NewItem 205 Industry Document

COMPREHENSIVE INDUSTRY DOCUMENT SERIES
COINDS/80/2009-10
Comprehensive Industry Document on

Electric Arc a Induction Furnaces
.10010`
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CLEAN E%
Central Pollution Control Board

Ministry of Environment Et Forests
Website : www.cpcb.nic.in ; email : cpcb@nic.in
March, 2010
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COMPREHENSIVE INDUSTRY DOCUMENT SERIES:

COINDS/ 80/2009-10
COMPREHENSIVE INDUSTRY DOCUMENT ON

ELECTRIC ARC & INDUCTION FURNACES
J\S
0c CLEAN 41,
lt*Tri
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Ministry of Environment & Forests
Parivesh Bhawan
East Arjun Nagar, Delhi-110 032
Website : cpcb.nic.in ; email : cpcb@nic.in
March, 2010
CPCB, 200 Copies, 2009-10
Prepared & Published by P R Division, Central Pollution Control Board at ENVIS Centre-01 on behalf of
Sh. J.S. Kamyotra, Member Secretary, CPCB
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441arorTr4

(A Govt. of India Organisation)
Ministry of Environment & Forests
Prof. S. P. GAUTAM
Chairman
FOREWORD
The Central Pollution Control Board (CPCB) brings out publications entitled
"Comprehensive Industry Document series (COINDS)" based on the industry-wise
studies. These documents are intended to cover various aspects of different categories
of industries in the country with respect to their number, locations, capacities, types
of product, usage of raw materials, process adopted, pollution generation, waste
minimization, pollution prevention & control measures; and formulation of Minimal
National Standards (MINAS). The present report entitled "Comprehensive Industry
Document on Electric Arc & Induction Furnaces" is latest one in this series being
published by CPCB.
The study for the report was conducted in association with Punjab State Council for
Science & Technology, Chandigarh. The help and assistance extended by the State
Pollution Control Boards and industries during the conduct of this study is gratefully
acknowledged. Sh. J. S. Kamyotra. Member Secretary led the team of Shri U. N. Singh,
SEE, Shri R. C. Saxena, SEE and Ms. Pavithra L. J. AEE, in preparing this volume.
It is hoped that this document would be useful to the secondary steel making industries,
regulatory agencies, consultants and others interested in pollution control.
I s ^
S. . Gautam
Chairman,
March 31, 2009
'Parivesh Bhawan' C.BC.D.-cum-Office Complex, East Arjun Nagar, Delhi-110 032

Tel.:+91-11-22307233, Telefax: +91-11-22304948
E-mail: ccb.cpcb@nic.in, website: www.cpcb.nic.in
CONTENTS
Title
Page
ChapterI
Introduction
ChapterII
Electric Arc Furnaces
Section 1: Introduction
Section 2: Industrial Scenario
Section 3: Manufacturing Process
Section 4: Sources of Air Pollution
18
Section 5: Field Study Results
21
Section 6: Emission Monitoring Results
36
Section 7: Pollution Control Technologies
42
Electric Induction Furnaces
45
45
47
48
Section 4: Sources of Air Pollution
51
52
Section 6: Monitoring Results
59
64
ChapterIV
Standards
70
ChapterV
Good Practices
71
ChapterIII
Comprehensive Industry Document on Electric Arc & Induction Furnaces
CHAPTER I - INTRODUCTION
1.1 Introduction:
Ever since discovery of steel, it has arguably proved its versatility as a material with a wide
range of critical applications over and over again. No longer is it just a material that is
inevitably used to build large bridges and huge structures. On the contrary, over the years,
it has come to be the officially acknowledged as a gauge for a country's development as
also as an engine of its growth. Be it something as trivial as safety pin or as sophisticated
as an automotive body, steel has found its unique application in all spheres of our lives as a
material.
1.2 Primary Vs Secondary Steel Industry
Primary steel making industries are those where steel is made through Blast Furnace /Basic
Oxygen Furnace (BOF) using iron ore. The secondary steel industry is that which makes steel
through electricity. Worldwide, there are broadly two major categories of steel players:
Integrated Steel manufacturing
Mini Steel mills/secondary producers
From the melting of the steel to rolling to final product, the processes are carried out in
integrated steel plants. Steel manufacturers therefore prefer this method due to inherent
advantages
Lower energy cost
Higher labor productivity because of elimination of intermediate processing and handling.
Superior quality.
Consistency and higher material yield
Less Waste.
With the time, electric furnaces are favoured over other type of furnaces for steel making.
The factors responsible for this transition are:
Producing high temperatures as compared to other furnaces.
Allowing quick rise and control of temperatures.
Electric furnaces enable concentrated heating.
No energy is spent to heat the fuel in case of fuel fired furnaces.
1
Lower exhaust gas losses as compared to conventional furnaces.
1.3 Classes of Electric Furnaces
The mini Steel segment/secondary producers comprise mainly two classes of furnaces
based on their electricity producing technology, apart from other manufacturing units like
the independent hot and cold rolling mills, re-rolling mills ,galvanizing and tin plating units,
sponge iron producers and so on. which are as:
Electric Arc Furnaces ( EAFs )
Electric Induction Furnaces ( IFs)
Electric Furnaces
Arc Furnaces
Induction Furnaces
Direct Arc Furnace
Submerged Arc Furnace
The EAF/IF units use scrap and sponge iron as raw material to produce steel. To a large
extent, the integrated mills and the mini mills differs only in the technology for making molten
steel. After the casting unit, both integrated steel plants as well as mini steel plants use the
same steel processing method. These producers have difference in technology because of
different:
Product mix
Management Styles
Scale of Operations
Process Economics
Cost Structures
Profitability
1.4 Raw materials used
The various raw materials used by this industry are:
SteelStainless Steel Scrap, Mild Steel scrap, Sponge Iron

2
Electrical Energy.
1.5 Production Capacity
In India, production of steel through electric route increased from 25% of the total steel
capacity in 1982 to 46% in 2003. In India, there are 34 EAFs based steel units with a total
installed capacity of around 12.5 million ton per annum. The production capacity of these
units was 4.5 million ton in 1999-2000. There are 900 IFs based steel units with a total
installed capacity of 10 million ton per annum. These units produced 8.5 million tones during
the year 2003-2004.
1.6 Major Clusters
The major clusters of EAF/IF are:

Ludhiana/Mandi Gobindgarh/Faridabad/DelhiNorth
Belgaum/ Coimbatore/Palaghat South
Durgapur/HoogliEast
Puneffhane/NasikWest
CHAPTER II-ELECTRIC ARC FURNACES

1.1 Direct Arc Furnaces
In the Direct Arc Furnaces, electric arcs are formed between the electrodes and the metal
being heated, which is thus a component of the electric circuit and is heated by the radiation
from the arcs. Direct arc furnaces are used to produce high carbon steels and low alloyed
steels.
1.2 Submerged Arc Furnaces
In the submerged arc furnaces, the arcs burn under a cover of solid charge which surrounds
the electrodes. The charge is heated by the heat generated by the arcs and by joule heat
formed on the passage of the current through the charge. SEAF is used for manufacturing
ferrosilicon, ferromangenese, ferrochrome and silico-manganese alloys.The SEAFs are open
from the top and the raw materials are being fed from the storage bins through chutes.
These storage bins contain different grades of raw materials and are being fed in to the SEAF
depending upon the properties of the finished product. In these furnaces, carbon electrodes
are used to create the electric arc. These furnaces are continuous in operation but molten
metal is being drawn intermittently.
In India, most of the electric arc furnaces are using Direct Arc furnaces.

2.1 Distribution of EAFs in the country
The following charts represent the state wise and region wise distribution of EAFs.
9%
East
n North
West
South
Total No of EAFs=34
Status of EAFs-Regionwise
Uttar Pardesh
3%
Chandigarh
3%
West Bengal
Chhatisgarh
3%
Goa
12%
Gujarat
9%
Rajasthan
Haryana
3%
6%
Jharkhand
Punjab
12%
6%
Karnataka
3%
Orrisa
3%
Maharashtra
28%
Kerala
6%
State wise distribution of EAFs

EAF are principle melting/refining units of mini steel plants producing carbon, alloy, special
steel and stainless steel for flat or products having long length applications. The processes
used in these units is divided into following major steps :
Preparation and charging of raw material
Melting and Refining of the melt.
Casting of molten metal into ingots, blooms and billet
The process flow chart showing various process steps used in an Electric Arc Furnace is given
Fig. 1
The EAF is a batch-melting furnace consisting of a large bowl shaped refractory lined
body with a dish shaped hearth. Typically the shell diameter is 2 to 4 m. The shell has
a refractory lining inside. The reaction chamber of the furnace is covered from above by
a removable roof made of refractory bricks held by a roof ring. The furnace has a main
charging door and a tap hole with a tapping spout. It is fed with a three phase alternating
current and has three electrodes fastened in electrode clamps which are connected by
means of a sleeve led flexible cables and water cooled copper tubes. The furnace rests on
two supports sectors which can roll on the furnace stand to tilt ping. The tilting motion
being affected by a rack mechanism. The furnace is covered by a refractory roof, which
has ports for three graphite electrodes. The electrodes are supported by arms, which allow
movement up and down.

Preparation of the charge material
V
Charging of the furnace
Melting
Dephosphorisation and Decarburisation (02 Lancing)
Deslagging
Adjustment of the composition
Tapping
Refining-Ladle/ADD
Pouring
V
Continuous casting
Fig: Manufacturing Process
UHP
der cooled
root
cucrgen
oveter oodocl
She porois
laming
oxy-fuet
burner
twere
feiraczrf
fratereal
OCcertitc
CO/torn
LIPPIng
111M...r.n.11
Fig: A typical diagram of EAF
Direct Rvacuatton
System
Graphite glectroder
during furnace charging
PurnaCe Shell
'PT
tapping
Rocker Tilt
--Teeming Ladle
Tilt Cylinder
Roof suspension
beam
Water Cooled Roof
Water Cooled
Cables
Working Platform
---Power Conducting Arm,
Fig: Elevation and Plan of EAF
3.1 Inputs to Electric Arc Furnace

The two major inputs to an electric arc furnace to get the desired product are:
Raw Steel
Energy
Input
Ferrous material (Steel, scrap, foundry returns, swaft,
pig iron...)
Alloying metal (ferro alloy)
Flux (Lime stone ...)
Energy (electricity, gas, oil)
Oxygen
Electrodes
Output
Metal alloy (steel) Dust (metal content refractory)
NOx CO2,C0
Organic air pollutants, HC
Metal oxide fumes
Slag (Ca02, Si02, MgO)
Waste refractories
7
enerse n-
faxing of 1
'ma prep.i
of furnace i
-r
E
deoxidising :secondary metallurgy
continuous casting
scrap,
fuels,
gases,
fluxes,
addtions
INPUT
EAF
LADLE TREATMENT
VACUUM TREATMENT
I.
CONTINUOUS CASTING
SYSTEM
a/1.W
Flow Diagram of EAF process
3.1.1 Raw materials
Raw materials and operating practices affect EAF efficiency and yield. The traditional EAFs
were using 100 WO cold scrap. With the time the industry has shifted towards using mix input
i.e steel melting scrap, sponge iron and cast iron. The steel melting scrap is process scrap,
old and discarded steel articles and components of machinery and ship breaking scrap.
Turning and boring mill cut ends of billets/rods and shredded scrap are used. The shift is
towards the enhanced use of sponge iron as it does not contain impurities i.e. copper and
other alloying elements, melts faster and ease to control the chemistry of melt. The reasons
for this transition are:
The availability of scrap needed to meet these requirements is limited to prompt
scrap. The scrap needed is imported from the international market.
Yield and energy consumption are both strongly dependent on the quality and physical characteristics of the iron units available.
3.1.2 Energy
Productivity is function of net rate of energy input. There are two major components of
energy which is put into the furnace i.e. Electrical Energy and Chemical Energy.
Electrical energy is dominant on the input side. For making one ne of steel, the energy
requirement is 450-650 KWH depending upon the type of raw material used. 50-60 % of the
total cost of production is of electrical energy. There are losses of this energy due to poor
quality of power supplied i.e. variation of voltage and frequency, trippings during melting
of metals. Thereby it becomes necessary to conserve heat by minimizing heat loss per
minute during the EAF process. The production can be increased with the application of good
transformer having high useful power and by reducing heat loss.
8
Chemical energy is concurrent with the electrical energy input and thus supplement it to
reduce the heat time. In this case, oxygen injections plays an important role in combustion
of oxidants in the furnace. Oxygen injection/lancing helps to burn the oxidants in the furnace
and release the chemical energy in the furnace.
Around 35 % of the total energy needed in the furnace is covered by chemical energy.
A pie chart showing energy input vs output
3.2
Preparation of Raw
material
The various qualities of metal feeds are stored in separate areas in order to allow the controlled
feeding of the melting furnace. Raw materials, including fluxes in lump and powder form,
deoxidants and refractories are normally stored under cover.
Sizing of scrap is important to maximize bucket density, better capacity utilization and
minimizing energy losses. Proper scrap sizing limits the number of required recharges,
thereby saving energy lost during roof swings and minimizing refractory damage due to
impact of heavy pieces at charge and flare of uneven charges. The metal charged in the
melting furnace is carefully selected and weighed to ensure the correct composition. Some
scrap sorting is carried out to reduce the risk of including hazardous contaminants. The
scrap is loaded into charging baskets in the scrap-yard or may be transferred to temporary
scrap bays inside the melting shop. In some cases the scrap is preheated in a shaft or on a
conveyor. The physical and chemical characteristics of the scrap have a direct influence on
the performance of EAF meld shop and its operating cost. Hence the scrap type and price is
crucial to the economies of Electric Steel Making.
9
3.3 Charging of Raw Material

The scrap is usually loaded into buckets together with lime or dololime which is used as a
flux for the slag formation. Lump coal is also charged at some plants. There are two main
methods of charging of the arc furnaces i.e. box charging and pan charging. Most of the
industries are using pan charging as box type charging in applicable in small furnaces. In the
pan charging, charge is loaded from a pan into the furnace from the top. With pan charging,
the charge of average density can be loaded in one go in 5- minutes. The roof of the furnace
is swung aside at the time of charging. The capacity of the pan is selected for an average
charge density of 1.0-1.2 ne/m3 . It is normal to charge about 50-60% of the scrap initially
with the first scrap basket; the roof is then closed and the electrodes lowered to the scrap.
After the first charge has been melted the remainder of the scrap is added from a second or
third basket. Some systems also permit continuous scrap charging. However in India usually
charging by means of buckets is applied.
Charging of Raw Materials
3.4 Melting and Refining of the melt

After the charging of the material into the furnace, the graphite electrodes are lowered
down into the charge and the current is supplied to them. The electrodes serve to supply
the electric current into the melting space of arc furnaces. The cost of electrodes per steel
amounts to 10 per cent of the total production cost. The high temperature of the electric arc
melts the charge beneath the electrodes, the molten metal flows down and accumulates in
the lowest middle part of the hearth. As the electrodes are being lowered down, they cut
wells in the charge 30-40 percent larger then the diameter of the electrodes. Usually the
electrodes comes to their lowermost position 30 minutes after switching on the current .Once
the first charge melts, second batch can be added to the furnace.
During operation in a furnace, the electrodes are burnt gradually owing to the oxidation by the
furnace gases and atomization by the electric arc. As an electrode becomes shorter, it should
be immersed more deeply in the furnace. After some time, it has to be replaced as can no
longer maintain arc. The electrode consumption per tonne of steel varies from 3-10 kg.
10

-1nnn=1=1n1111.nnn
". n
:0
40
60
80
;CO '70 74 0
MN.
rJ
Furnace rapacil,y, t
Graph showing electrode consumption per tonne of steel
3.4.1 Addition of Lime and Coke

Lime and other materials are added to the charge during the melting in the furnace
so as to facilitate the formation is slag. The slag entraps various impurities i.e scale
and rust from the melt. Foamy slags are desirable in the furnace as:
It reduces the heat losses from the furnace.
There is fast heating of the melt as the slag covers the surface.
It saves from refractory from deterioration.
It covers metal from cooling, saturation with gases and carbonization of electrodes.
The average slag formation from a electric arc furnace is 10-15 %. The composition of the
slag is as:
Average (%)
36.2
Range (%)
28.6 41.8
12.4
7.2 17.7
22.1
18.3 -27.0
7.4 0.1
Fe0
Mn0
8.4
0.7
0.5 1.0
14.8
4.0 29.6
TiO2
1.2
0.39 2.7
Na20
0.3
0.1
0.11 0.57
Compound
Si02
Ca0
Mg0
Al203
K20
0.1-0.23
11
3.5 Oxygen lancing

Oxygen in electric furnace steelmaking not only beneficial for metallurgical reasons but
also for increasing productivity requirements. Oxygen for metallurgical reasons is used for
decarburisation of the melt and removal of other undesired elements such as phosphorous,
manganese, silicon and sulphur. In addition it reacts with hydrocarbons forming exothermic
reactions. Oxygen injection results in a marked increase in gas and fume generation from the
furnace. CO and CO2 gases, extremely fine iron oxide particles and other product fume are
formed. Oxygen is added to the furnace to burn the CO as excessive levels of CO can result
in explosion besides wastage of useful heat.
3.6 Deslagging
After the charge is completely melted, the foam slag is taken out from the charging door. The
furnace is tilted to an angle upto 15 degrees and the molten slag is taken out.
3.7 Tapping
There are two main methods of tapping the molten metal from the furnace.
Side tapping
Eccentric Bottom Tapping
Side tilting mechanism are employed with smaller capacity furnaces and is mounted on a
column at the furnace side. In this system, the furnace has to be tilted to angle as high as
45 degrees. The limitation of this kind of system is that the removal of liquid metal from the
furnace is not 100 % thereby effecting the yield.
In the eccentric bottom type tapping, the furnace rests on 2 to 4 supports sectors which
roll on a horizontal stand. The spout end is made to protrude far from the furnace. In this
system, tilt angle upto 15 degrees is required and this system is very effective. Most of the
12
industries are switching over to this technology because of high yield. In this system, liquid
steel with minimum slag carry over goes into the ladle.
.
Outputs
Inputs
Scrap
Kg/t
1,080-1,130
Steel Melt
Kg/t
1,000
Total Energy
- Electrical Energy
- Oxygen
Graphite electrodes
Lime
Coal
Kwh/t
Kwh/t
m3/t
Kg/t
Kg/t
Kg/t
650-750
Slag
Kg/t
100 -150
345-490
24-47
3-10
30-80
13-15
Specific Input/Output balance of typical EAF plants
3.8 Secondary Metallurgy

Secondary metallurgy covers the processes and treatment of molten steel after the tapping
of the primary steel making furnace up to the point of casting. It is typically carried out
at ladle treatment stations/AOD. These stations in bulk steel production plants are usually
located around a vacuum generation system or arc heating unit. Other minor stations are
based on inert gas or powder injection equipment. Various techniques for refining of metal
are :
Ladle Refining Furnace
Argon Oxygen Decarburization ( AOD )
3.8.1 Ladle Refining Furnace

Ladle refining refers to the metallurgical processes that occur in the ladle. These include
alloying, deoxidizing, degassing and the reheating and stirring of the bath. Ladle refining
affords the steelmaker with the flexibility to control the processing of heats in order to
achieve greater production efficiencies and superior metallurgical traits.
3.8.2 Argon Oxygen Decarburisation (AOD) Converter for Steel Refining:

The AOD converter is a special vessel for refining steel. It is mainly used for the
production of low carbon stainless steel The molten metal is transferred directly from
the melting furnace (generally electric arc or induction) into the converter. As shown
in figure, oxygen (for the removal of carbon, silicon) and argon gas (for the stirring
action) can be injected into the converter by means of tuyeres positioned in its lower
part, to refine the metal. The converter is equipped with a tilting mechanism in order to
allow filling and emptying. Steel with a precise chemistry can be produced using AOD,
but at a high cost.
13
AOD USED FOR REFINING
The first phase of the refining process consists of a decarburisation, through the injection of
oxygen into the converter. This is a refining operation that holds the carbon content of the
charge material within a specific range, as required. Decarburisation is initiated by injecting
oxygen into the metal bath. This creates a strong stirring action during which carbon in the
melt is burned. At the same time the "boiling" burns out silicon, and flushes out hydrogen and
nitrogen from the metal bath. All impurities (oxides) are trapped in the slag. During melting,
lime may be added to bring the slag to the proper basicity. When the carbon reaches the
required concentration, oxygen injection is stopped and silicon and manganese are added
to halt the boiling reaction, especially in the production of stainless steels. A dilution of
the oxygen with argon or nitrogen assists the oxidation of carbon in preference to metallic
elements such as iron, chromium, etc., leading to very good metallic yields. Consequently
Al or Si and limese are added to the metal and argon is injected in order to remove sulphur.
The continuous gas injection causes a violent stirring action and an intimate mixing of slag
and metal which can lower sulphur values to below 0.005%. The residual gas content of the
treated metal (hydrogen and nitrogen) is very low. All impurities are trapped in the slag and
removed with it. After temperature and alloy adjustment the metal is transferred to ladles
for pouring.
Compound
Consumption (per ne of steel)
CO
50 120 m3
02
25 60 m3
Al
1 2.5 kg
Lime
10 20 kg
Si
1 2 kg
Ar
1 5 m3
3.8.3 Vacuum Oxygen Decarburisation Converter (VODC) for Steel Refining:

The VODC (Vacuum Oxygen Decarburization Converter) operates in such a way that molten
steel is contained in the converter, which is attached to vacuum pumps, steam ejectors and an
14
argon gas source. Two distinct processes are carried out in the vacuum treatment of stainless
steel to obtain a higher quality level. VODC involves decarburization under reduced pressure.
This process is used for making special grade steels. The VODC allows the production of
ultra-low-carbon and nitrogen grades. The technique consumes 1 Nm 3 Ar per ne of steel,
shows low chromium oxidation and has a silicon consumption of 3 5 kg/tone.
First, the steel is decarburized by introducing oxygen into the melt. At the same time, some
argon is injected from the converter base. The converter uses vacuum pumps to lower the
partial pressure of carbon monoxide, to such an extent that effective decarburization can be
carried out without oxidising too much of the chromium. This first process is similar to AOD
decarburization, but less argon is needed thanks to the lower total gas pressure and the
process is much more efficient. The oxidized chromium is reduced back to liquid steel with
aluminum.
The second process involves degassing. The converter is brought under deep vacuum (1-5
mbar) using a water ring pump and steam ejectors. Slight argon bubbling is continued in order
to maintain an effective steel movement. At the very low pressure, gaseous impurities such as
hydrogen and nitrogen are eliminated effectively. At the same time, the total oxygen content
and the sulphur content are drastically decreased, which is beneficial for the mechanical
properties of the end steel. Low alloyed steels are normally only degassed.
The VODC process provides specific steel qualities, which cannot be obtained by other
methods. The total oxygen content is also lower than what is typical for electric arc melted
and AOD-treated steel, because a high level of oxide inclusions are removed form the melt
during the VODC process, and most of the dissolved oxygen is further removed during the
degassing phase.
In operation since
1995
1994
1995
Furnace type
DC
UHP furnace
carbon steel
100
140
DC
UHP furnace
carbon steel
125
130
DC
UHP furnace
carbon steel
120
120
scrap
water cooled side walls
and roofs
EBT
600,000
oxygen gas burners
scrap
water cooled side walls and
roofs
EBT
600,000
oxygen/natural gas burners
(7)
coal
2ndhole, ladle furnace
dedust-ing, big furnace
enclosure
Produced steel grades

Tapping weight [t]
Nominal apparent power
of current transformer
[MVA]
Raw materials
scrap
Cooling system
water cooled side walls
and roofs
EBT
Tapping system
Capacity [t/a]
750,000
Additional burners
gas burners
Additional fuels
Emission collection
measures
coal
2ndhole, hood
coal
2ndhole, roof hood
15
Off gas cleaning system
post combustion
chamber with additional
burners
quenching (air) fabric
filter
post combustion chamber post combustion fabric filter

with additional burner
quenching (water) fabric
filter
Energy aspects
recovery of waste gas

heat
ladle furnace vacuum
degassing
recovery of waste gas

heat
ladle furnace
vacuum degassing
Secondary metallurgy
water cooled ducts

ladle furnace
3.9 Continuous Casting:

The liquid steel is usually cast continuously. Ingot casting is also still applied for some grades
and applications. Continuous casting is a process which enables the casting of one or a
sequence of ladles of liquid steel into a continuous strand of billet, bloom, slab, beam blank
or strip Steel is tapped from the ladle into a tundish from which it is distributed at a controlled
rate into water-cooled copper moulds of appropriate dimensions.
To prevent the solidified shell from sticking, the mould is oscillated in the direction of casting
at speed greater than the casting speed and a mould lubricant is added in powder form or
vegetable oil. The strand is continuously withdrawn and is further cooled using direct water
sprays. At a point where solidification is complete the strand is cut to required lengths using
automatic oxygen cutters.
The prerequisites for the production of electric steel are the provision of the inputs scrap,
additions, fluxes, and electrical energy, as well as the regular preparation of the furnace, i.e.
its lining with different types of refractory material to protect the furnace shell against high
temperatures and chemical and physical strain caused by inputs, heat, and slag.
16
The charging of the furnace is usually performed in batches: Two to four buckets with,
possibly sorted, scrap are inserted through the open top into the furnace. Each charge
is partly melted while the next bucket is prepared. Some systems also permit continuous
scrap charging, however, in India usually charging by means of buckets is applied.
According to the desired steel quality, fluxes (e.g. lime) and additions (e.g. carbon,
chromium) are also added. The addition of these materials can take place both during the
charging step and the oxidation step, if the furnace is equipped accordingly. To melt the
charged inputs, the movable roof is closed, the graphite electrodes (introduced through
the roof) are lowered, the electric arcs are ignited, and the melting phase starts. To lower
the consumption of electrical energy and to accelerate the melting process, oxygen or
a fuel-gas mixture can be injected by special types of lances or by oxy-fuel burners to
generate process heat.
The oxidation step normally starts after the melting is completed. It mainly aims to
reduce the carbon content of the heat and to oxidise undesired tramp elements. During
the melting and the oxidation phase a slag is formed on top of the heat. The slag
helps to remove tramp elements like sulphur, silicon, phosphor, and manganese. Besides
this positive metallurgical effect, a foamy slag on top of the melt is also important for
achieving an efficient energy transfer and in particular the protection of the furnace
shell. Another positive effect of the foamy slag is a reduction in noise caused by the EAF
process. Usually, at the same time as the injection of oxygen, also pulverised coal, or socalled foaming coal, is injected by lances into the furnace to intensify the boiling. Stirring
and bath agitation may also be supported by the injection of inert gases (e.g. argon or
nitrogen) by means of tuyeres.
The tapping step starts with the tilting of the furnace to tap the slag, as the highly
oxidized slag is not desired in the following secondary metallurgy processes. Then the raw
steel is tapped at temperatures of about 1,600 to 1,680C. The tapping angle required
to almost empty the furnace varies from 12 to 42, depending on the tapping system.
In practice, eccentric bottom tapping (EBT) is commonly used nowadays. This system
allows a slag free tapping and tapping angles of about 12, which are favourable for cost
savings (caused by the reduction of tap-to-tap times, reduction of heat losses, shorter
power cables).
17

In general, secondary metallurgical processes, e.g. in a ladle furnace, follow the tapping step.
Some refining may also take place in the EAF itself, but nowadays the fine adjustment of
the desired steel quality is not performed in the EAF. The secondary metallurgical treatment
of the steel melt in an extra vessel was established for the increasing demands on the steel
quality, requiring additional post-melting treatment, and the possibility of reducing tap-to-tap
times by using the EAF only for the melting of steel.
Break-Up of the Total Cycle Time of a 25t Furnace:
OPERATION
MINUTES
Charging
2-3
Melting
120-130
Oxygen Lancing
10-20
Deslagging
10-15
Pouring
3.5
Total Cycle Time
145
r
'landing of
FPuts, prep
of furnace
crs1" I 0, r
i
c, i %I
Fa I
..
_ I
= I
'''' I
o lEi
r
r
7 I ....
1
-
11
;I
c.
I c- I
`,I!5-
deoxidising
secondary metallJrgy
cont InJOJ s casting
LADLE TREATMENT
VACUUM TREATMENT
CONTINUOUS CASTING
SYSTEM
scrap,
energy.
fue s
gases
times,
aodil ions
INPUT
EAF
1 vat tom
Schematic Diagram of EAF manufacturing process
Section 4: Sources of Pollution

4.1 Air Emissions from Electric Arc Furnaces
The emissions from EAFs originate from the charging, melting, and refining operations and
during tapping of the furnace.
During charging, dust and dirt will be emitted from the open furnace body. When charging
a hot furnace (for instance when melting with a molten heel in particular), any combustibles
such as grease, paint or oil ignite and give rise to smoke plumes of burnt and partially
burnt organic material and dust particles. The mechanical abrasion of the furnace lining also
generates additional dust.
18
During melting, heating of the scrap generates metal oxide fumes that significantly increase
during the decarburisation treatment. The injection of oxygen gas into the molten metal
develops significant quantities of iron oxide fumes, which leave the furnace as red clouds.
The addition of slag forming materials increases the furnace emission, but only in small
quantities and only for a short time. Minor emissions occur during the transfer of the molten
metal into a ladle or holding furnace. Emissions from the melting operation itself are referred
to as primary emissions. Secondary emissions are the fumes and dust originating from the
charging and tapping.
As per the literature, particulate emissions rates vary from 6- 20 kg/tonne of charge with
an average of 10-12 kg/tonne. The highest emission rates are recorded at the beginning
of the melt cycle and during the decarburisation treatment. The composition of the dust
primarily depends upon the grade of the steel being produced. The available literature does
not report the quantities and the composition of the secondary emission being generated
during charging, tapping and de-slagging operations. The nature of these emissions depends
on the cleanliness of the raw material w.r.t. oil, grease, paint etc.
Emission Charging
EmissionAnnular Spaces Around Electrodes
Emission Deslagging
19
EmissionTapping
4.2 Air Emissions from AOD:

Dust emissions from AOD are comparable to EAF furnaces dusts, both in quantity and quality.
AOD dust emissions have lower levels of residuals (organic) from the scrap charge, but on
the other hand have a higher level of metal oxide (Cr, Ni), as it is mainly stainless steel which
is processed in AOD vessels.
The effluent from the mouth of an AOD consists of carbon monoxide and inert gas. The rate
of carbon monoxide evolution depends on the tuyres oxygen injection rate and the oxygen
efficiency, or per cent of oxygen which reacts with carbon. This oxygen efficiency, or "carbon
removal efficiency", as it is traditionally labeled in AOD operation, varies during the course of
an AOD blow, in response to combined variables of the bath carbon level, temperature, bath
chemistry, and the mixture of injected gases.
The CO and inert gas mixture leaves the vessel approximately at the bath temperature.
The CO mixture exiting the vessel is mixed with excess air in order to fully burn the CO to
CO2 very early in the exhaust duct. This is done to prevent the presence of combustible or
explosive mixtures persisting downstream into the duct to the filter equipment.
4 .3 Submerged Electric Arc Furnace (SEAF):

This is one of the other types of electric arc furnace working on the same principle. SEAF
is used for manufacturing ferrosilicon, ferromangenese, ferrochrome and silico-manganese
alloys. The capacity of these furnaces varies from 20-60 T/day. The raw materials used are
ores of these alloys, coal, coke, dolomite, quartz etc.
In SEAF, silica is reduced by carbon in the presence of iron. The rest of the carbon will be
consumed to transform silica to silicon carbide. Mass and enthalpy balances are used to
determine the carbon and electricity requirements of the process. The recycling of silicon
monoxide is promoted by maintaining a bed of a certain height so that evolved gases are
cooled owing to heat exchange between the gas and solid phases.
20
The SEAFs are open from the top and the raw materials are being fed from the storage bins
through chutes. These storage bins contain different grades of raw materials and are being
fed in to the SEAF depending upon the properties of the finished product. In these furnaces,
carbon electrodes are used to create the electric arc. These furnaces are continuous in
operation but molten metal is being drawn intermittently.

A comparative statement of the industries visited for the purpose of study is as under:
North
The electric arc furnaces in this region are located in Ludhiana, Mandi Gobindgarh, Chandigarh
and Faridabad.
S. No. Description
1
No, of furnaces
2
Melting Capacity (T/
heat)
3
Heat time (in minutes)
Tapping system
4
5
6
7
9
10
Power Consumption
(KwH/T)
Transformer rating
(MVA)
Raw material
Sponge IronPig Iron, HMS & Plant
returns
Others
Graphite electrode
consumption (Kg/T)
Technology for air
pollution control
Type of containment
Ilk
11
Supplier of APCD
Unit A
1
30
Unit B
1
30
Unit C
1
25
Unit D
2
25 each
Unit E
1
10
Unit F
2
15 each
135
EBT
EAF-725
LRF-130
Aux- 70
16
120
Side
Tapping
515
87
90
20
270
Side
tapping
900
125-150
100-125
5.5
140-150
Side
tapping
525
9
180-210
Side
tapping
500-600
65-150
100-125
4.15
210-240
Side
tapping
530
150-200
70-80%
20-30%
50%
30%
75%
25%
40-45%
55-60%
10%
65%
3-4
20%
2.9
3.2
25%
3.6
3-4
Reverse air
Pulsejet
Pulsejet
bag filter
bag filter
bag filter
Swinging
4th hole
4th hole
4th hole
evacuation evacuation
elbow
evacuation
M/s
Thermax
Ltd., Pune
M/s.
Thermax
Ltd. Pune
M/s. Nikko
Tech.,
Mumbai
3.75
Pulsejet
Pulsejet
Reverse air
bag filter
bag filter
bag filter
Swinging
4th hole
4th hole
evacuation 4th hole
evacuation
elbow
evacuation
& Roof
extraction
system
M/s.
M/s.
M/s. Nikko
Thermax
Thermax
Tech.,
Ltd. Pune Ltd. Pune Mumbai
21
12
13
14
15
16
17
Flue gas volume

(including LRF) (in
Nm3/hr)
Fan pressure (mm)
and
Motor rating (kw)
Flue gas cooling
arrangement
54000
58000
118800
60000
35000
62500
485
500
600
600
500
75
Air to
air heat
exchanger
2.0
200
Air to
water heat
exchanger
2.0
345
Dilution
damper
56
Air to
water heat
exchanger
0.80
500
Spray
scrubber
1.5
150
Air to
water heat
exchanger
2.2
1.3%
1.5%
0.38%
1.35%
1.2%
8-9%
10%
5-7%
5.5%
10-12%
Capital cost of APCD

(Rs. in Crores)
Dust generation (% of 0.5%
production capacity)
Slag generation (% of 12.96%
2.5
EAST
Sr.No. Description
1
No, of furnaces
2
3
Melting Capacity (T/heat)

Heat time
(In minutes)
Tapping system
Power Consumption (KwH/T)
Transformer rating (MVA)
Raw material
Sponge IronScrap
Graphite electrode consumption (Kg/T)
Technology for air pollution control
Type of containment
Supplier of APCD
Flue gas volume (including LRF)
Fan pressure (mm) and
motor rating (kw)
Flue gas cooling arrangement
(Rs. In Crores)
Dust generation (% of production capacity)
Slag generation (% of production capacity)
15T each
240
4
5
6
7
8
9
10
11
12
13
14
15
16
17
22
Unit G
Eccentric Bottom Tapping

750
7.5 (including LRF)
5-10%
90-95%
7 (including LRF)
Cyclonic scrubber followed by Bag filter
Canopy hood with pneumatic swivel arrangement
Designed by the industry itself
27000 m3/hr (at 5000C)
Water cooled duct
WEST
Sr.No Description
Unit H
Unit I
Unit 3
Unit K
Unit L
Unit M
No. of furnaces
Melting Capacity (T/heat)
48
40
20
45
50
30
Heat time (in minutes)
120
90
240
70
100
150
Tapping system
Side
tapping
Side
tapping
Side
tapping
EBT
EBT
EBT
Power Consumption
(KwH/T)
458
Transformer rating (MVA)
Raw material
20
21
7.5
36
36
18
Sponge Iron-
15%
20-25%
20%
25-30%
40-50%
Pig Iron
20-25%
30%
25-30%
100/0
HMS, Scrap, Scull etc.
60-65%
75-80%
50%
40-50%
40-50%
Graphite electrode
consumption (Kg/T)
2.5-2.8
2.7-2.8
2.5-3.0.
3.60
2.8
3.5
Technology for air

pollution control
Pulsejet
Bag filter
Reverse
air bag
filter
Reverse
air bag
filter
Pulsejet
Bag filter
Reverse
air bag
filter
Reverse
air bag
filter
10
Type of containment
4th hole
4th hole
4th hole
4th hole
4th hole
4th hole
evacuation evacuation evacuation evacuation evacuation evacuation
11
Supplier of APCD
M/s Nikko M/s Nikko

M/s
Techs,
Thermax Techs,
Ltd., Pune India
India
12
Flue gas volume (including 1,08,000

LRF) (In Nm3/hr)
90,000
13
Fan pressure (mm) and
880
motor rating (kw)

14
15
M/s Flakt
India Ltd.
M/s Nikko
Techs,
India
M/s Nikko
Techs,
India
38,000
90,000
90,000
550
20kg/cm2
900
388
315
410
336
Flue gas cooling

arrangement
Cooling
duct &
Natural
cooled
ducts
Cooling
Cooling
duct & Air duct
to Air heat
exchanger
Cooling
duct & Air

to Air heat
exchanger
2.65
2.50
350
2.30
150
Cooling
duct
3.0
(Rs. In Crores)
16
Dust generation
1.8T/day
5T/day
1.0T/day
17
Slag generation (% of
12.5
4-5
10
1T/day
8%
8-10%
23
Specific Input/ Output balance of typical EAF plant

Inputs
Outputs
Scrap
Kg/t
1,080-1,130
Steel melt
Kg/t
1,000
Total energy
Kwh/t
650-1150
Slag
Kg/t
100-150
Of that: Electrical
energy Oxygen
Kwh/t
m3/t
450-900
20-30
Dust
Kg/t
5-15
Graphite electrodes
Kg/t
2.5-4.0
Lime
Kg/t
30-80
Refractory
breaks
Kg/t
n.a.
Coal
Kg/t
13-15
Plant scrap
Kg/t
n.a.
Lining
Kg/t on average
1.9-25.1 8.1
Noise
dB(A)
125-139
Water
Closed loop
SUBMERGED ELECTRIC ARC FURNACES (SEAFs)

Sr. Description
No.
Unit N
Unit 0
Unit P
100 TPD from 3 furnaces
110 TPD from 3 furnaces

Fe-Mn and Si-Mn
No. of Furnaces
Production Capacity 80TPD from 4 furnaces
Finished product
Si-Mn alloys
High carbon
(Si-16%,Mn- 60%
Iron-21%, C- 3%)
Medium Carbon (Si-25%,
Mn- 55%
Iron-19.5%, C- 0.5%)
Fe-Cr alloys
Tap to tap time
2.5 hrs per heat
2 hrs. per heat
Fe-Mn ( 2 hrs)
Si-Mn (2.5hrs)
Transformer rating
3.5 MVA (2 nos.)

7.5 MVA (2 nos.)
7.5 MVA each
5.5 MVA, 6.5 MVA and 12

MVA
Raw material
composition
Mn ore 64%
Quartz- 3.5%
Dolamite 1.5%
Fe-Mn slag 17%
Coal/coke -14%
Ore -2.6T/Tof alloy

Coke -0.8T/Tof alloy
Fluxes-0.2T/Tof alloy
Mn ore- 30-46% Coke70-75% Dolamite

-250kg/T for Fe-Mn
Power consumption
(Kw/ton)
5000(medium carbon)
4000(High carbon)
Slag Generation
40 TPD from all the 4

furnaces (high carbon)
and 25 TPD (medium
carbon)
15000T/annum from all

the 3 furnaces
1Ton per ton of metal
Ultimate disposal of Land filling

slag
Dumping in storage yard
The slag of Fe-Mn used

as raw material and slag
of Si-Mn dumped in low
lying areas
24
10 Technology for Air

pollution Control
Venturi scrubber
Pulsejet bag filter
11 Capacity of APCD
80,000 m3/hr. for each

furnace
Pressure- 400 mm
4.5 TPD from 4 furnaces
1,00,000 m3/hr (3500C)

Pressure- 350 mm Motor100 hp
12 Dust generation
13
Disposal of dust
14 Capital cost of
APCD
The dust contains Mn20%, C-30%, Iron-5%,

ash 40%. The dust after
briquetting is used as raw
material.
80 lacs for all the 4
1.50 crores for 3 furnaces
furnaces
Cyclone followed by
Pulsejet bag filter for
5.5 MVA & 6.5 MVA and
scrubber for 12 MVA
90 kg/day from 6.5 MVA

furnace
There are around 11 sub merged electric arc furnaces in Durgapur manufacturing Ferrosilicon, Ferro- manganese, Ferro- chrome and Silico-manganese alloys. Each unit on an
average is having 3 submerged electric arc furnaces with capacity varies from 20-60 ton/day.
The raw materials used are ores of these alloys, coal, coke, dolomite, quartz etc.
In submerged electric arc furnace, silica will be reduced by carbon in the presence of iron. The
rest of the carbon will be consumed to transform silica to silicon carbide. Mass and enthalpy
balances are used to determine the carbon and electricity requirements of the process. The
recycling of silicon monoxide is promoted by maintaining a bed of certain height so that
evolved gases are cooled owing to heat exchange between the gas and solid phases.
The submerged electric arc furnaces are open from the top and the raw material is being
fed from the storage bins through chutes. These storage bins contain different grades of raw
material and are being fed into the furnace depending upon the properties of the finished
product. In these furnaces, carbon electrodes are used to create the electric arc. These
furnaces are continuous in operation but molten metal is being drawn intermittently.
Most of the units have provided hoods at a distance of 1.2-1.6 m from the top of the furnace
to contain the dust emissions followed by air pollution control device in the form of venturi
scrubber/bag filters Unit N has provided side suction hoods. This design was found to be good
in comparison to other furnace as the industry has provided shutters in the gap between the
furnace and the hood to cover it to the maximum possible extent. The shutters are operated
for pushing of the raw material by motorized trolley and for electrode removal. The hood is
supported on brick masonry structure.
Observations
Capacity and Tap to Tap time
The economical furnace size is limited by the power transformer size and the power the electric
25
supply grid can provide. The following table shows relation among capacity, required size and
electrical equipment. The melting rate depends largely on the capacity of the transformer as
seen from the following table:
Nominal
capacity
of furnace
(103kg)
2
Outside
diameter of
furnace core
(m)
Metal bath
depth (mm)
2.178
300
Diameter of
electrode
(mm)
175
Capacity of transformer Secondary

(MVA)
voltage (RP
RP
HP
UHP furnace) (V)
1.5
5
2.743
400
200-250
3
10
5
3.353
400
300-350
20
3.962
450
7.5
350-400
4.572
30
650
400-450
12
50
5.182
750
450-500
18
60
5.486
850
500
20
70
5.791
850
22
500
80
6.096
900
500
25
100
6.400
950
500-550
27
120
6.706
1000
550-600
30
150
7.010
1000
600
30
170
7.315
1050
600
35
200
7.620
1100
600
40
400
9.754
1200
700
Notes: RP: Regular power, HP: High Power, UHP: Ultra High Power
5
7.5
12
18
25
27
30
35
40
45
50
60
70
-
15
22
30
35
40
45
50
60
70
80
100
150
180/80
200/100
220/100
240/100
270/120
330/130
400/130
400/130
430/140
460/160
500/200
500/200
500/200
560/200
Source: Cast Product Hand Book, 4th Edition, Japan Cast Product Association
The capacity of the furnaces studied during the visit varies from 9 T/ heat to 48 T/ heat. The
tap to tap time varies from 70 minutes 270 minutes. The tap to tap time depends upon the
availability of power supply and the capacity of the transformer. A unit having a transformer
capacity of 36 MVA for their 45T furnace has tap to tap time of 70 minutes whereas another
unit having a transformer capacity 6.5 MVA for 22 ton furnace were having a tap to tap time
of 270 minutes.
Because of electric power supply limits, electric power costs and furnace efficiency
considerations, oxygen, natural gas and coal are increasingly used to augment the melting
process. The most powerful furnaces approach a power to tapped steel weight ratio of
1 MVA per ton.
Segregation of Scrap
Most of the furnaces are segregating their scrap before charging into the furnace. This would
help in to avoid explosions due to presence of some explosive material in the scrap such as
bomb shells.
Composition of Raw Material
The desired steel quality is a relevant factor for any resulting impacts of electric steel
production on the environment, as different types of steel grades require different input
26
compositions and generally different treatments cause changes in the yield and chemical
composition of dusts and slag. It has been observed that the composition of the raw material
i.e. sponge iron, pig iron, HMS, shredded scrap, plant scrap etc. varies within the industry,
industry to industry and region to region depending upon the availability of these materials
in the market and their cost.
Electric steel making plants use scrap of various grades and qualities usually consisting of
a mix of old, new and plant scrap depending upon the quality of steel to be produced. The
plant scrap arises during production and further processing of crude steel within plant limits.
New scrap arises during the manufacture of finished products while old scrap denotes scrap
returning after utilization of finished products. It has been experienced that the quality of the
scrap being used by the industry varies to a great extent depending upon its availability in
the market and its cost.
Tapping System
Most of the electric arc furnaces have side tapping but the furnaces being commissioned
in the recent past have eccentric bottom tapping system that discharges the molten metal
vertically into a ladle placed underneath the furnace by a transfer car.
Foamy Slag Practice
Most of the furnaces now-a-days are using Foamy Slag Practice by injecting carbon powder
into the furnace.
Energy efficiency
Electric arc furnace is only 55% energy efficient with 45% of the total furnace energy input
going into losses such as slag (10%), water cooled panels (12%), the off-gas system (21%)
and miscellaneous other losses (2%).
Sr. No.
1
Ill
liplp
Description
(h))
Energy utilized in melting

Heat of molten metal
27.16
Heat of molten slag
6.28
Losses
Structural losses
3.32
Cooling water losses
29.02
Radiation heat loss through electrode hole
1.25
Radiation loss through slag hole
7.75
Radiation during charging of furnace when lid is open
5.59
Heat loss in exhaust gases
19.63
Total
100
27
-11
Heat generated by
chemical reaction
Heat generated by
combustion
Input heat
; /KIT
Electric power
(61.7 %)
453.5kwh/ton
H
oxidation
electrodes
by
Heat generated by
combustion oil in the
scrap
Heat generated
when slag is formed
EAF 6320 CI kceitton=735kwhiton(
Output heat
%)
Heat loss through

furnace body
sensible heat In molten

steel (54.6 %) 345x10
kcal/ton
----
water
Electric power loss

sensible heat in
exhaust gas
130x10 kcal/ton
OR 151kwh/ton
sensible heat in
slag
E.A.F. HEAT FLOW CHART
The structural losses and losses in cooling water depend on the duration of heat. Whereas the
radiation losses through slag hole and charging of furnace can be reduced by simple house
keeping measures. The heat wasted in exhaust gases can be recycled for the preheating of
scrap.
Power Supply
Most of the electric arc furnaces in operation in the country are supply AC power to the
arc using three graphite roof electrodes. Most of the DC furnaces are single electrode units
where the current flows down
from the carbon electrode which serves as a cathodes to an anode in the bottom of the
furnace. A few DC furnaces are of three electrode type where the current flows from each of
the top electrodes to a bottom return electrode.
The electrode consumption in case of DC arc furnace is 50-60% lower than that of
conventional three phase AC furnace. Electrical consumption can be 3-5% lower than
AC operation. It is also reported that noise level of the DC furnace are lower and lower
maintenance cost are claimed due to lower refractory cost. Capital cost of DC installation
are higher than AC system, however reduced operating cost can recoup this difference.
The equipment needed for DC melting has the same configuration as that of a conventional
28
AC furnace. The exceptions are the addition of the bottom electrode (anode), DC reactor
and thyristor rectifier.
Use of Ladles
Most of the electric arc furnaces are using 2-4 ladles for the transfer of molten metal
from electric arc furnace to ladle refining furnace and from ladle refining furnace to
concast plant. It was observed that one unit in Punjab is using only one ladle in the whole
process upto to concast plant thereby avoiding the emissions being generated during
pre-heating of the ladles with furnace oil beside savings on account of consumption of
furnace oil.
Pre-heating of scrap.
Pre-heating of scrap is a practice to tap the waste heat in the exhaust gases. Scrap preheated to a temperature of 600-7000C leads to reduction in tap to tap time by 8-10 minutes
and a saving of 30-40 kWh/t in electrical energy. This would need to reduction in dust
emissions in the flue gas.
The literature reveals that the waste gas contain energy content upto 150 KwH/T of which
more than 80 KwH/T can be chemical energy. During the project studies, it was observed
that one of the units had explored the viability of heating the scrap through waste gases. The
industry achieved reduction in energy consumption by 25-30 kWh per ton of steel produced
with a capital investment of Rs. 50.0 lacs whose present value is around Rs. 1.5 crores.
Presently the industry is not practicing the pre heating of scrap because of following practical
problems:
Difficulty in taking out the pre-heated raw material from the pre-heating chamber thereby resulting in production loss.
The system is only viable for units using 100% shredded scrap as other raw materials
such as turning and boring and sponge iron gets partially melted in the pre-heating
chamber. This would result in chocking of the system.
Excessive pressure drop across the pre-heating chamber thereby requiring more energy
to suck the emissions from the furnace.
May be due to the formation of organic emissions
May be due to the formation of dioxins
May be due to the non control over the temperature in the scrap pre heater. However,
this option has to be evaluated thoroughly with respect to economic viability.
29
Containment of air emissions

The emissions from the electric arc furnace are mainly of three types:
Primary emissions
Secondary emissions
Fugitive emissions
The primary emissions are produced in the electric arc furnace during melting and possibly
during the refining periods in the secondary metallurgy vessels. The secondary emissions are
the emissions being
generated during charging, heat tapping, slag tapping and opening around the electrodes.
Whereas fugitive emissions being generated during various raw material handling operations
such as receiving, unloading, storing and conveying.
It has been experienced that majority of the electric arc furnaces have provided 4th hole
evacuation to contain the primary dust emissions which contributes 90% of the total emissions
as per the literature. Most of the furnaces do not have any arrangement to contain the
secondary as well as fugitive emissions whereas in one of the furnaces , it has been studied
that the secondary emissions contributes 30% of the total average cycle time of 120 minutes.
The secondary emission as well as fugitive emissions escape into the furnace building and
are vented through the roof vents.
One industry at Haryana have installed Roof extraction system on the EAF in addition to 4th
hole evacuation to contain the secondary dust emissions. Further Unit A & E have installed
swinging duct connecting water cooled elbow and water cooled duct to combustion chamber
which swings with the movement of electric arc furnace thereby capturing the dust emissions
being generated during de-slagging and tapping period. Another industry have provided
swiveling canopy hood above their electric arc furnace in place of 4th hole evacuation
to contain the primary as well as secondary dust emissions. The hood is being operated
pneumatically and is 5-6 feet below the overhead crane and around 2 feet above the top of
the graphite electrodes thereby not hampering any of the furnace operations.
Cooling Arrangements
The gases from the electric arc furnace after entering the combustion chamber have
temperature anywhere between 500-8000C. These gases have to be cooled before taking to
the bag filter. Normally the bag filter operates at about 1200C. The gases can be cooled by
following ways.
Dilution
Water cooling heat exchanger
Air cooling heat exchanger
30
Each of the above has its own advantages and disadvantages. If we cool the gases by dilution
as observed in one of the units, the gas volume becomes very high i.e. 1,20,000 Nm3/hr for
their 22T furnace. The power consumption of the fan becomes very high i.e. 350Kwh. The
other option is to cool the gases in a water cooling heat exchanger which has the highest
heat transfer coefficient i.e. between 25 to35. The capital cost is lower and the cooling was
reported to be very effective. Water cooling heat exchanger has got the advantage that
the whole unit is very compact and economical in running. Air cooling heat exchangers are
comparatively bigger in size and the heat transfer coefficient is anything between 10 to 15.
Number of blowers are used for cooling the incoming hot flue gases. This system has the
advantage of switching off a number of blowers whenever the temperature of the flue gas
was observed to be low thereby savings on account of energy consumption. Moreover there
are less operational problems because it does not have any interconnecting water cooling
pipes, cooling tower and pump. The capital cost of water cool heat exchanger is 75% of that
involved in air cooling heat exchanger.
Further it has been observed that Unit H has provided natural cooling of the duct by vertically
extending it around 500 ft in U shape pattern to bring down the temperature of the flue gas.
The photographs of the cooling arrangement are shown below:
111 1 111 1 11 11 1 1 , i ii-o
Natural cooling of the flue gas (Fig.1)

31
Natural cooling of the flue gas (Fig.2)
Flue gas Volume

It has been observed that the volume of the flue gas of electric arc furnace with matching
ladle refining furnace varies from 2300-4500 Nm3/hr per ton capacity of the furnace.
Air Pollution Control Measures
Most of the electric arc furnaces have installed the following technology to control the pollution
being generated from the electric arc furnace.
Reverse air bag filtration
Pulse Jet bag filtration
Most of the air pollution control systems having reverse air bag filtration technology were
designed and supplied by M/s Nikko technologies, Japan, whereas the system having pulse
jet bag filtration technology were designed and supplied by M/s Thermax Ltd., Pune. Both of
these technologies are efficient and adequate to achieve the emission standards of 150 mg/
Nm3 prescribed by the Central Pollution Control Board.
It has been observed that in case of reverse air bag filter, there is no exhaust chimney for
venting the clean gases after filtration thereby making it impossible to collect the samples
for checking the PM. The clean gases after bag filtration are being released from the louvers
32
provided in the side walls of the shed. The total height of the bag filter was observed to
be around 20-25 m. Some of the observations made for both the technology are detailed
below:
Sr. Reverse air bag filtration
Pulse jet bag filtration
No.
1 The fan is located before the bag house and is The fan is located after the bag filter and is designed
designed to operate with dust laden gases. This to operate the clean gases. The efficiency of the
would result in low efficiency of the fan thereby fan is more with less power consumption.
higher power consumption
High air to cloth ration would result in smaller bag
area.
Low air to cloth ratio would result in more bag

area.
Life of the filter bags is long. Retaining rings are Life of the filter bags is short because of contact
stitched into the filter bags and hence the filter with cage and each other
does not come into contact with each other.
Checking of the filter bags during operation is

always possible from clean gas side as dust setting
is on the inner side of the filter bag.
Checking of the filter bags is always from dust

attaching side i.e. dust deposition on the outer side
of filter bag and hence no inspection is possible
during operation.
Filter bags can be replaced within the bag house

during operation
Cage housing the filter has to be taken out for

replacing the filter bags. Consequently, plant has
to be shut down for change of bags.
Compressed air is required at 5kg/cm2 for bag

filter cleaning.
Compressed air is required at 5-7 kg/cm2 for

proper and effective cleaning of the bags.
As a part of exhaust gas is only used for reverse As a separate compressor is required, the additional
draft, the power consumption for fan is about 30- power consumption is 100-150 KW.
40 KW.
One electric arc furnace have installed cyclonic scrubber followed by bag filter to control
the pollution from their 15T furnace. The operation and maintenance of the bag filter is
very important otherwise the bag filter would result in increased pressure drop, reduced
suction and consequent bypassing of the bag house. The bag cleaning operation should
always be off line. It has been observed in some of the industries that the pulse jet
bag filter cleaning is online because of to reduce the capital cost of the equipment. It
is experienced that the industries are not maintaining the proper maintenance schedule
regarding:
Manometer readings at regular intervals to check the pressure drop across the bag
filter.
Checking of the bags at regular intervals.
Checking of the solenoid valves.
Time periods for the disposing off the dust from the bag filter
Checking of the ID fans
Record for the replacement of bags
33
Dust generation
The electric arc furnace dust is collected from the bag filters. The following factors are mainly
responsible for dust generation:
Transformer rating
Quantum of oxygen used.
Product mix
Amount of carbon in the charge
Quality of scrap
It has been observed that the average rate of dust generation varies between 5-15 kg/T. An
average electric arc furnace of 30T capacity with production capacity of 270TPD generates
about 400T of dust per annum. The industry is dumping this hazardous dust either within the
industry or in the low lying areas. No industry was found to have any metal recovery system.
Some of the industries have constructed the dedicated sheds to store this dust after filling
it in HDPE bags. The composition of the dust varies to a great extent depending upon the
product mix and the quality of the scrap. The analysis of the dust carried out by CPCB and
various other agencies are tabulated below:
Sr. No.
1
2
Description
*Concentration (mg/g)
Cd
0.188
Cr
0.740
Cu
1.060
Fe
428.50
Ni
0.124
Pb
15.500
Zn
192.00
*Source: CPCB
Sr.
No.
Description
Nikko Techs,
India (%)
SAIL, Ranchi
(%)
Metallurgical
& Engg.,
Consultants
India Ltd.,
Ranchi (%)
Thermax Ltd.,
Pune (%)
Iron oxide (Fe2O3)
25-30
19-60
19-65
40.5
Calcium oxide(CaO)
2-12
2-22
1-22
3.03
Silica (S102)
10-20
1-9
2-14
4.07
Zinc Oxide (ZnO)
20-35
0-44
Lead oxide (PbO)
3-4
0-4
Managese oxide (MnO)
2-5
3-12
4-12
31.41
34
7
8
9
10
11
Magnesium oxide
(MgO)
Nickel oxide (NiO)
Aluminium oxide
(Al203)
Chromium oxide
(Cr2O3)
Molybdenum oxide
(Mo203)
FeO
Fe
P
S
2-4
2-15
2-38
10.0
3-5
1-2
0-3
1-13
1-13
8.0
9-12
0-12
0.5-1.0
4-11
2-8
5-36
0-1
0-1
1-4
16 C
1-11
17 Alkalies
Source: Proceedings of the workshops on, "Environmental Pollution in Secondary Steel Industry held at Delhi
from 21 st 23 rd August, 1991.
12
13
14
15
It has been seem from the above table that the composition of the dust varies with the
composition of the raw material depending upon the grade of steel to be manufactured.
Further it also varies with the type of scrap used, which itself varies with respect to its
origin.
Disposal of dust
It has been observed that some of the industries do not have proper arrangements for the
storage and disposal of dust being collected below the hoppers of bag filter house. Few
industries have provided screw conveyors underneath the bag filters to collect and transport
the dust into
overhead silos from where it is loaded into the trucks for ultimate disposal. It has been
experienced that when we take the dust from overhead silos to the trucks, certain amount of
dust flies into the environment. This problem of flying of the dust repeats again when dust is
unloaded from the truck to some place. This dust is very light and fine like a talcum powder.
It flies into the environment with moderates winds.
Slag generation
Like dust generation, slag generation is an indispensable part of the steel making process.
Slag usually arise at two places within an electric steel making plant. In the EAF itself,
an oxidizing slag is formed, furthermore a refining slag is obtained in the secondary
metallurgical process. The yield and composition of secondary metallurgy slags are
dependent upon the desired output. Significant differences exist between the amount
and composition of the slag obtained by the production of commercial steels and high
grade steel.
35
In electric arc furnace, slag generation varies from 100-150kg/T of steel produced. Most of
the industries are dumping their slag into the low lying areas after separation of iron by the
magnetic separators.
Fluid coupling with fan of APCD
Generally the fan is installed at the back end of the pollution control system consumes very
large amount of power. The flue gas volume varies with variation in temperature of the
furnace at different times. It has been observed that the pollution control system which
was designed with respect to peak volume when comes to valley (low volume) because of
variation in temperature, the efficiency of the fan comes down. The fan was observed to be
operating all the time irrespective of whether the furnace was under charging or furnace
was under tapping. When the fumes were not generated even then the fan was running
continuously, may be with the damper partially closed but consuming fairly good amount of
power.
One unit at Punjab have installed fluid coupling with the fan so that the speed of the fan
can be varied according to the pollution load. As we know that volume of the flue gases is
proportional to the speed of the fan, the pressure is proportional to the square of the speed
and power consumption is proportional to the cube of the speed. By incorporating this
system, the industry have been able to save considerable amount of energy.
Refractory Material
The total refractory material consumption generally consist of two components. One part
arises by the breaking out of refractory material, another part results from continuous wear
and tear and is combined with slag or dust. The total average consumption of refractory
material (furnace and secondary metallurgy vessels) depends significantly on the type of
steel produced. It has been observed within the following limits:
Carbon steels 12 kg/ton (approximately)
High grade steels (alloyed and stainless steels)- 22-32kg/ton (approximately)
The average refractory consumption in the furnace itself amounts to 8 kg/ton of steel
produced. The consumption of refractory depends on the produced steel quality, further
more on the tap to tap time and the heat temperature of tapping.
During study, to the various clusters of electric arc furnaces, the following units have been
identified for emission monitoring:
The performance evaluation of the technology provided for air pollution control from electric
arc furnace, work zone monitoring and ambient air monitoring was carried out. The results
of the monitoring are tabulated below:
36
Particle size distribution

Northern region
Particle size
range
(in micron)
Unit I (A) (EAF)

0/0 of particles
(Number basis)
Unit II (E) (EAF)

0/0 of particles
(Number basis)
Western region
Eastern region
Unit III (H)

(EAF)
0/0 of particles
(Number basis)
Unit IV(N)
(SEAF)
0/0 of particles
(Number basis)
6.6
49.16
22.17
41.60
31.4
27.90
20.68
27.50
10-20
40
7.99
13.84
13.30
20-30
10
4.48
11.62
7.80
30-40
2.72
10.87
3.60
Above 40
7.75
20.83
6.80
0-2
2-10
Performance monitoring of the air pollution control system

S.
No.
Description
M/s Aarti
Steel, (EAF)
M/s
Starwire
India Ltd.,
Faridabad
(EAF)
M/s
Mohindera
Ugine Steel,
Raigad
(EAF)
M/s Shyam Ferro Alloys,

Durgapur (SEAF)
Furnace capacity (T/

heat)
30
10
48
80 TPD
Raw Materials
Sponge iron
70-80%
10%
15%
20-30%
65%
85%
Mn ore Quartz
Dolamite Fe-Mn
slag Coal/coke
25%
Pig iron, HMS

returns
&
Plant
Others
64%
3.5%
1.5%
17%
14%
Design Flue gas volume 54,000

including LRF (Nm3/hr)
16,000
1,08,000
40,000 (for 2 furnaces)
Technology for Pollution Pulse Jet Bag

Filter
Control
Pulse Jet Bag

Filter
Pulse Jet Bag

Filter
Venturi Scrubber
Monitoring Results
Inlet
SI.
No.
Inlet
Outlet
Outlet
Inlet
Outlet
Inlet
Outlet
42,727
42,381
Charging Oxygen Charging Oxygen

lancing
lancing
Flue gas volume

(Nm3/hr)
Temperature (OC)
18432
17375
27099
31070
13853
280
290
62
67
129
13407 1,24,370 1,04,942

88
145
80
190
40
6.50
4.36
10
9.6
5.5
6.4
31.30
5.74
33.84
10.99
CM PM (mg/Nm3)
1168
817
40
37
462
35
15,520
330
140
40
, 1 PM (kg/tone)
11
1.48
23
35
137
ll Velocity (m/sec)
11 SO2 (mg/Nm3)
7
NOx (mg/Nm3)
1.8
4.2
3.4
12
10
8.4
64.30
-
37

8
CO (mg/Nm3)
VOC as Total
hydrocarbon (mg/
Nm3
10
Work Zone
112
110
98
96
12 ppm
5 ppm
16
189
ppm
Below
detectable
limit
SPM (8 hrly sample)

(mg/m3)
6.25 -6.52
2.83
2.57 -2.59
0.78
1.73
2.85-3.11
APCD working
APCD not working
CO
Monitoring of AOD & Roof extraction system of Unit II (E).

Sr.
No.
1
2
3
4
5
APCD-AOD
Description
Stack after APCD
Location
62
7.14
59,982
110
Temperature (OC)
Velocity (m/sec)
Flue gas volume (Nm3/hr)
PM (mg/Nm3)
APCD Roof extraction

system
Stack after APCD
(APCD not in operation)
46
10.79
41,040
70
Monitoring of LRF of Unit I (A).

Particle size distribution
Particle size range (in micron)
Sr. No.
1
2
3
4
5
6
7
8
9
38
% of particles
0-2
29.5
2-10
55.0
10-20
11.5
Above 20
4.0
Description
Location
Temperature (OC)
Velocity (m/sec)
Flue gas volume (Nm3/hr)
PM (mg/Nm3)
SO2 (mg/Nm3)
NOx (mg/Nm3)
CO (mg/Nm3)
VOC as T.hydrocarbon (mg/Nm3)
APCD-LRF
Stack before APCD
105
9.5
3,366
1182
4
8
90
Below detectable limit
Ambient Air Quality Monitoring Of Unit III (H)

Sampling Stations
Station 1 (Weigh bridge)

1st sample 12 hrs (19.00 -7.00)
2nd sample -12 hrs (7.00-7.00)
Station 2 (Main receiving station)
1st sample 12 hrs (19.00 -7.00)
2nd sample -12 hrs (7.00-7.00)
Station 3 (Rolling mills)
1st sample 12 hrs (19.00 -7.00)
2nd sample -12 hrs (7.00-7.00)
RSPM
(micro gram/m3)
SPM
(micro gram/m3)
178
462
275
577
38
132
188
443
129
p132
290
274
The size of the particles varies with the variation in the composition of the raw material
depending upon the product to be manufactured. It also depends upon the quality of the
scrap which again varies with respect to its origin.
Observations on the monitoring results

The monitoring results indicated in the above tables was studied thoroughly and the
observations made are as under:
UNIT I (A)
It has been observed from Table that only 6.6% of the particle are up to 2 micron which
seems to be on the lower side. The following observations were made after critically examine
the Table 3 of performance monitoring:
The flue gas volume monitored before bag filter as 17375-18432 Nm3/hr against design volume of 54000 Nm3/hr.
The efficiency of the pulsejet bag filter for the control of PM was found to be around
96% during melting as well as during oxygen lancing.
The SO2 and NOx emission before APCD was found to be in the range of 5 -12 mg/
Nm3.
The temperature of the flue gas monitored before the bag filter was found to be 28029000. The sample was taken before the air heat exchanger provided by the industry.
The temperature at this point should be around 500-7000C as per the literature.
The flue gas volume in the stack was monitored as 28,000- 31,000 Nm3/hr against
flue gas volume of 17,375 18,432 Nm3/hr monitored before the bag filter. This
increase in volume of the flue gas may be due to the cooling of the flue gas with air
heat exchanger.
39
The PM levels before the bag filter was monitored to be 817-1168 mg/ Nm3 during
oxygen lancing and charging time respectively. Whereas the literature, the PM levels
at the time of oxygen lancing should be more than during charging time. These emissions levels were found to be on the lower side. This may be because the industry
was operating the fan at around 30,000 Nm3/hr against designed of 54,000 Nm3/
hr. These emission may be much more if the industry has operated the fan at its designed capacity i.e. 54,000 Nm3/hr.
The SPM levels in the work zone was found to be around 6.5 mg/Nm3 during oxygen
lancing stage and 6.2 mg/Nm3 during the charging and melting stage against the
permissible limit of exposure (time weighted average concentration 8 hrs) of 10
mg/ m3 as indicated by The Factories Act, 1948
The CO levels in the work zone was found to be around 3 mg/m3against the permissible limit of exposure (time weighted average concentration 8 hrs) indicated by
The Factories Act, 1948 of 55 mg/ m3 .
The PM level before the bag filter in case of Ladle refining furnace was monitored as
1182 mg/Nm3.
The Volatile Organic Carbon (VOC) both in case of the electric arc furnace and ladle
refining furnace before bag filter was found to be below detectable limit.
UNIT II (E)
From Table, it has been observed that 49% of the particles are up to 2 micron and 28% of
the particles are between 2-10 micron. The following observations were made after studying
the Table 3 of performance monitoring in light of the size of the particles:
The flue gas volume monitored to be around 14,000 Nm3/hr against design flue gas
volume of 16,000 Nm3/hr which seems to be right.
The temperature monitored before the bag filter as 1290C seems to be right as the
sample was taken after the water heat exchanger.
The PM levels before the bag filter was found to be 462 mg/Nm3. These levels are
found to be on the lower side. This may be due to the composition of the raw material (sponge iron -10%, Pig iron 5%, Heavy melting scrap/plant returns 60% and
others 25%) as the industry is manufacturing high carbon stainless steel.
The efficiency of the pulsejet bag filter for the control of PM was found to be around
96%.
The CO emissions before and after APCD was found to be 12 ppm and 5 ppm respectively.
The SPM levels in the work zone was found to be 2.83 mg/m3 whereas the permissible limit of exposure (time weighted average concentration 8 hrs) of 10 mg/ m3
as indicated by The Factories Act, 1948 .
40
The PM levels at the inlet of Argon Oxygen Decarburiser (AOD) could not be monitored as the duct before bag filter was totally water cooled.
The PM levels monitored after the air pollution control device provided on roof extraction system to contain the secondary emission was found to be as 70 mg/Nm3. The
APCD was out of operation at the time of sampling. Hence the PM levels of 70 mg/
Nm3 shall be treated as inlet levels.
The VOC emissions were monitored at the inlet of APCD but nothing was detected.
UNIT II(H)
The 22% of the particles were monitored to be between 0-2 micron and 21% of the particles
were found to be between 2-1 micron. The observations made are as under:
The flue gas volume monitored to be 1,24,000 Nm3/hr against design volume of
1,08,000 Nm3/hr. This may be because of excess dilution.
The temperature of the flue gas was monitored as 1450C. The sample was taken
before the cooling arrangement. The temperature at this point should be around 5007000C as per the literature. This may be due to excessive flue gas volume because
of higher dilution.
The PM levels in the flue gas were monitored to be as 15,520 mg/Nm3. This may be
due to higher flue gas volume and high pressure of the fan i.e. 880 mm against average pressure of 500 mm.
The SPM levels in the work zone was found to be around 2.6 mg/m3 whereas the
permissible limit of exposure (time weighted average concentration 8 hrs) of 10
mg/ m3 as indicated by The Factories Act, 1948 .
The RSPM levels in one of the sampling stations at weigh bridge was found to be 178
and 462 microgram/m3prescribed standards of 150 microgram/m3 (Table 6).Whereas
the SPM levels at this station was found to be 577 microgram/m3 against the prescribed standards of 500 microgram/m3.
UNIT IV (N)
Unit IV is having a submerged electric arc furnace for the manufacture of high carbon and
medium carbon Si-Mn alloy. The industry has provided common venturi scrubber for two of
its furnaces having capacity as 40,000 Nm3/hr. The industry is manufacturing high carbon SiMn (Si-16%, Mn-60%, Fe-22% and C-3%) and medium carbon Si-Mn (Si-25%, Mn-55%, Fe20% and C-0.5%). The raw materials used are manganese ore, coal, coke, dolomite, quartz.
The tap to tap time is 2.5 hours. The industry has provided side suction hoods to contain the
dust emissions followed by venturi scrubber. The design of the hood was found to be good
in comparison to other SEAFs as the industry has provided shutters in the gap between the
furnace and the hood to cover it to the maximum possible extent. At the time of monitoring,
the furnace was running at 60% of its capacity due to power failure.
41
The observations made are as under:

The flue gas volume monitored to be around 42,000 Nm3/hr against design volume
of 40,000 Nm3/hr. This seems to be all right.
The PM levels before the air pollution control device was monitored to be as 140 mg/
Nm3. This seems to be on the lower side as the stack standards for the same are 150
mg/Nm3. This may be due to poor suction of the flue gases.
The NOx and CO levels before the air pollution control device was monitored to be as
137 mg/Nm3 and 189 ppm respectively.
The SPM levels in the work zone was found to be 1.73 mg/m3 when the APCD was not
in operation and 0.78 mg/m3 when the APCD was in operation against the permissible limit of exposure (time weighted average concentration 8 hrs) of 10 mg/ m3
as indicated by The Factories Act, 1948.

7.1 Containment of emissions
7.1.1 Fourth Hole Evacuation
Majority of the electric arc furnaces have provided 4th hole evacuation to contain the primary
dust emissions which contributes to 90% of the total emissions. This type of extraction
technology is state of the art in modern EAF steel making for the collection of primary
emissions and is recommended. A schematic diagram showing the same is as under:
Combustion and
dilutior air
baghouse
Stack
w.?tz .:ool,:c1 duct
Electrtc Arc
furnace
Combustion
chamber
\\/\\/\// / J I
Nam Evac,izqon
DIRECT EVACUATION SYSTEM
7.1.2 Swinging duct system

It has been experienced that in majority of the EAFs, the fourth hole elbow for the containment
of dust emissions remains static. As a result, the dust emissions during de-slagging and
tapping period escape the water cooled fourth hole elbow. It is recommended to install a
swinging duct system connecting fourth hole water cooled elbow and water cooled duct
leading to combustion chamber in the existing furnaces for the containment of dust emissions
being generated during de-slagging and tapping period. The swinging duct swings with the
swing of electric arc furnace at time of de-slagging and tapping operations. As a result, the
42
emissions going out from the sheds for a period 30-40 minutes out of a total cycle time 120
minutes at the time of de-slagging and tapping operations were captured in the air pollution
control device In some of the furnaces, it stands demonstrated.
7.2 Secondary Emission Control System
Most of the furnaces do not have any arrangement to contain the secondary emissions being
generated during charging of the raw material, from openings around the electrodes, tapping
and de-slagging operations. These emissions would contribute only 5 to 10% of the total
emissions.
It is recommended that canopy hoods by compartmentalizing the upper portion of the shed,
not interfering with the overhead crane and electrodes, be installed high above the furnace
to contain the secondary emissions. The roof and the sides of the sheds are sealed.
However the provision for capturing secondary emissions does not seem to be feasible in the
existing furnaces because of the inadequate strength of the roof structure and movement of
the over head cranes/gantry. Whereas it is worthwhile to provide for capture of secondary
emissions in new furnaces proposed to be set up. A velocity of 200-250 fpm should be
maintained between the furnace and the hood with duct velocity as 3500-4000 fpm.
The volume flow rates for well designed canopy hoods usually range from 2, 50,000 acfm
at 1500F, depending on the furnace size. Hoods should be sized to match the rising plume
at the hood face taking into account the dispersion of emissions by objects such as scrap
buckets and cranes.
7.3 Air Pollution Control Technology
Most of the electric arc furnaces have either installed pulse jet bag filtration technology or
reverse air bag filtration technology. The efficiency of pulse jet bag filtration was found to
be between 93-98%. The efficiency of reverse air bag filtration technology could not be
evaluated as most of the air pollution control system do not have stack to vent out the clean
gases after bag filtration. The clean gases after bag filtration are being released through
louvers provided in the vertical side walls of the shed of bag filter.
It is recommended that both the technologies i.e. reverse air bag filtration and pulse jet bag
filtration are highly efficient to the tune of 99.9% and either of the technology can be used
for the control of the particulate emissions. But in case of pulsejet bag filter, the cleaning of
the bags should be off line. The bag filter shall be provided in compartments preferably in five
compartments with 25% extra capacity so as to attend the necessary repairs/replacements
without interrupting the furnace operation.
7.4 On line emission monitoring
It is proposed that the industry should provide online stack monitoring kits to monitor the
suspended particulate matter in the exhaust gases. The cost of the kit is around Rs. 4 lacs.
43
7.5 Total cost of the APCD

Type of APCD
Bag Filter
Capital cost
(Crore)
2.5
0 & M cost/
annum (Crore)
Total 0 & M cost/annum considering

life of equipment as 7 years (Crore)
0.53
0.89
The annual turnover of 30 T/heat EAF was reported to be 400 500 crores. The environmental
cost works out as 0.2% of the annual turnover much below the limit of 3% as per the
requirement of National Enviornment Policy 2006.
7.6 Collection and Disposal of dust
It has been observed that most of the industries do not have proper arrangement for the
collection and disposal of dust. As a result, part of the dust flies back into the environment
because of the cross currents. It is proposed that a belt conveyor covered from the top and
sides shall be provided underneath the hopper of the bag filter to collect the dust through
rotary feeder. This dust is being conveyed to the storage silos through conveyor belts. From
storage silos, it is being filled in HDPE bags through mechanical means as like in cement
plants. The stitched dust bags can be disposed off to the hazardous waste landfill sites.
Alternatively the dust can also be disposed off after its pelletisation.
7.6 General
The structure of a charging crane should be considered so as not to obstruct the ascending stream from the furnace.
The melt shop layout has a significant influence on the design of the furnace secondary emission control system. Heat sources in a melt shop such as ladle heaters and
the continuous casting area should be isolated from the electric arc furnace melting
and refining area. It is because the heat from ladle heaters and continuous casting
area does not contain any dust and is being emitted outside the sheds without dedusting.
A canopy hood should be centralized without separating. Induced air through building
openings should be directed to the furnace and be emitted through a main canopy
with the aid of ascending stream caused by heat convection. Location of the opening
at various areas of the building should be designed to eliminate stagnation points.
Excess air infiltration into the furnace and ductwork should be reduced to the lowest
level possible in order to reduce the loading to the system. A damper should be provided in DEC duct system to control the draft of the furnace.
Cross drafts must be kept to a minimum near the furnace to prevent the emissions
from being blown away from the hood.
44
CHAPTER III: ELECTRIC INDUCTION FUNRACES

Introduction
Induction furnaces are used to melt both ferrous and non-ferrous metals. There are several
types of induction furnaces available, but all operate by utilizing a strong magnetic field
created by passing an electric current through a coil wrapped around the furnace. The
magnetic field in turn creates a voltage across, and subsequently an electric current through,
the metal to be melted. The electrical resistance of the metal produces heat, which in turn
melts the metal. Induction furnaces are made in a wide range of sizes. Because there is no
contact between the charge and the energy-carrier, the induction furnace is suited for the
melting of steel, cast iron and nonferrous metals, so long as a suitable lining material can be
found. Products made by the industry are as :
Mild Steel Ingots for structural purposes.
Stainless Steel Ingots for making utensils,wire rods and wires.
Low alloy steel castings for engineering applications.
Stainless steel castings for heat and corrosion resistant components.
Alloy steels for forging industry and grinding media.
Cast iron castings
1.1 Emergence of Electric Induction furnaces
Most of EAFs / IFs are recycling the steel scrap, as there is shortage of scrap in the country.
Since early 70"s to 1985, around 150 EAFs were installed with a capacity of over 9 million tones
in various parts of the country. However, in the meanwhile, Induction furnaces technology
came into the country in early 80's. Induction Melting Furnaces in India having capacity 500
kg to 1 ton were first installed to make Stainless Steel from imported Stainless Steel Scrap. By
1985-86, the technology of making Mild Steel by Induction Furnace was perfected by Indian
Technologists by putting up of bigger capacity furnaces. By 1988-89, 3 tones Induction
Furnaces were become common in India. In 1991-92, more Induction furnaces having bigger
capacity were installed all over India. Now-a-days, furnaces upto a maximum capacity of 20
ton/heat are being used. India is the only country in the World using induction furnaces on
a large scale to manufacture secondary steel. .
1.2 Preference to Induction Furnaces over Electric Arc Furnaces
India is the first country using Induction Melting Furnaces for making mild steel. The bulk of
structural quality mild steel for long products is manufactured by Induction Melting Furnaces.
During 2001-2002 period over 4.3 million tones of steel were produced by Induction Furnaces,
which has reached a level of 4.7 MT in 2002-03. The EAF units have also installed Induction
45
melting furnaces. There are several reasons for the popularity of Induction Melting Furnaces
for making steel.
They consume less power comparing EAF's. Expenditure on electrode is nil.
They use lesser quantity of refractory. Initial investment is less on plant and equipment. Thus, there are economic advantages in making steel through Induction Furnaces route.
The environmental pollution in case of EAF is much more than Induction furnaces.
The only snag of steel production through induction furnace route is of capacity limitation .
1.3 Types of Induction Furnaces
There are two main types of induction furnaces.

Iron Core Induction Furnaces
Core Less Induction furnaces
Most of the industries are using coreless induction furnaces as this system is much more
efficient as compared to Iron Core furnaces because of efficient melting and long furnace
life.
The coreless IF is a batch-melting furnace containing a water-cooled copper coil, the inside of
which is internally refractory lined. The outside is insulated and enclosed in a steel shell. The
furnace body is mounted in a frame equipped with a tilting mechanism. A coreless induction
furnace is normally a refractory-lined bucket-shape refractory, the top of which is open for
charging and deslagging operations.
Fig. Core Less Induction Furnace
46

Distribution of IFs in the country
The following charts represent the state wise and region wise distribution of IFs.
West Bengal
5%
Andhra Pardesh
3%
Uttar Pardesh
7%
'Others
5%
Chattisgarh
5%
Daman
5%
Uttaranchal
2%
DNH
2%
Tamilnadu
10%
Goa
2%
Gujarat
6%
Rajasthan
5%
Haryana
2%
Jharkhand
3%
Karnataka
7%
Punjab
14%
Kerala
3%
Pondicherry
3%
Orrisa
4%
Maharashtra
7%
State wise distribution of IFs
47
Comprehensive industry Document on Electric Arc & Induction Furnaces
Section 3: Manufac ;ring Process

A process flow diagram of the steel plant using Induction Furnace is as below:
Preparation of the charge material
Charging of the furnace
Melting
De-slagging
Adjustment of composition
Tapping
Pouring in moulds
Filled Moulds
if
According to the capacity, the furnace is charged by a lifting magnet, bucket skips, a vibrating
conveyor or manually. A large number of foundries use induction furnaces for producing
relatively small lots in a large variety of compositions. The induction furnaces are producing
500 kg 22 tonne per charge. Most of the induction furnaces are having capcity 3 T/charge.
With the time, the industries are putting furnace having capacity of 10 T, 12 T, 16 T and
22 T/ charge. Bigger units having production capacityl6 22 T/charge are putting concast
machines and Ladle Refining Furnaces ( LRF ) The furnaces are classified based on their
frequency of the current supplied :
High frequency furnaces (200 1000 KHz) supplied from valve generators.
Medium frequency furnaces (500 1000 KHz) supplied from rotary or thyristor convertors.
Low frequency furnaces (50 Hz) which are fed directly from the mains.
Depending on the installed power density and the melting practice the thermal efficiency can
exceed 80%, but usually ranges from 60 to 70%.
The coreless induction furnace can be designed to operate at any frequency from 50 Hz
upwards. The induction heating of liquid metal causes a stirring effect. The lower the
frequency of the primary current, the more intense is the stirring. Therefore, in a mains
48
frequency furnace working at 50 or 60 Hz, the turbulence is greater than in one operating at
higher frequency.
Coreless Induction Furnaces of various sizes
The frequency of operation affects the current penetration. The higher the frequency, the
lesser the penetration depth. This affects the minimal charge piece size and the effective
furnace size. 50 Hz furnaces are not practicable at capacities below 750kg. At 10 kHz, charge
pieces less than 10 mm in diameter can be heated, so furnaces as small as 5 kg capacity can
be used. Frequencies are usually limited to 250 to 350 Hz (in the case of variable frequencies),
as at higher frequencies metal homogenisation becomes insufficient. Higher frequencies are
used in special cases, such as with very small furnaces.
/1 3.1 Inputs to Induction furnace
11
There are two major inputs to an induction furnace.

Raw material as steel
Electrical Energy
3.1.1 Raw material as steel

The various input materials fed in the furnace are:
Shredded steel melting scrap mostly imported from USA.
Heavy steel melting scrap mill cut ends or old steel components.
Light steel melting scrap such as turnings and steel sheets.
Old cans & coated steel sheet cuttings.
[
Pig Iron/Cast Iron

Direct Reduced Iron
Ship breaking steel scrap.
49
3.1.2 Energy
The major source of energy in these plants is electrical energy. The average electricity
consumption for making one tonne for liquid metal is 600 1000 Kwh. In induction furnaces,
60 % of the cost of production is on electrical energy. In induction furnaces, raw material in
various proportions is mixed and put in the furnace. The typical heat losses from a coreless
induction furnace are shown below:
Total energy
supplied - 100 %
Transmission
losses - 3 - 5 %
Radiation losses
without lid 6 - 8 %
Coil losses
17 23 %
Mostly
> absorbed
by cooling
water
Lining - conducted
heat losses - 3 - 10
3.2 Preparation of raw material and Charging to the furnace

Raw material of various types is mixed into desired proportions to get the final product. Raw
material is taken near the furnace floor with the overhead crane. Raw material is either fed
manually to the furnace from the top or fed by the overhead crane.
3.3 Melting and Refining
Once the first batch is fed into the furnace, electric current is given and by magnetic
induction, the material gets melted. Once the material is melted, second batch of raw
material is added into the liquid metal in the furnace. Some alloying elements and lime are
added for adjustment of composition and for slag formation. Slag is removed from the top
of the furnace.
50
ty
S,
in
;s
The Data for 3 Tonne Medium Frequency Induction Furnaces

Sr.
No.
General Scrap Used Charge Mix
01
80% sponge iron
02
50% sponge iron or more
+ Mixed Scrap
24 Hr. Working
No. of Heats
Lining Life Per

Tonne
Power-KWH
Consumption
09
40 heats
820 Units
10% CI & mixed scrap
12
50-65 hetas
760 Units
03
30% HMS + 30% sponge &rest

mixed scrap + CI
13
60-75 heats
700 Units
04
30% HMS + rest loose mixed scrap
14
90-100 heats
700 units
05
15% LMS bundle + 15% turning

bundle + 50% HMS + rest mixed
scrap
14-15
100-125 heats
690 Units
06

bundle + 40% shredded scrap+
rest mixed scrap
15
100-125 he ats
670 Units
07

bundle + 40% shredded scrap +
20% HMS + rest mixed scrap
15-16
100-125 heats
650 hetas
08
15% HMS bundle + 15% turning

bundle + 60% shredded scrap +
rest mixed scrap
15-16
100-125 heats
650 Units
3.3.1 Refining in Ladle Furnace

The furnaces having batch capacities 16 T-22 T are providing Ladle furnaces for adjustment of
the chemistry of the bath.In smaller capacity furnaces, the refining is done itself in induction
furnace.
3.4 Tapping/Pouring in Moulds

After a cycle time of 90-120 minutes, the liquid metal is poured into the moulds for the
manufacturing of Ingots, Billets etc. Bigger plants have provided continuous casting
machines.
Section 4: Sources of Pollution

4.1 Nature of Emissions:
Since no coal or fuel is burned in the induction furnace and no refining procedures are
executed, the emissions solely depend on the cleanliness and the composition of the charged
material. Two major categories of emissions can be distinguished. The first, and major,
category relates to the charge cleanliness, e.g. rust, dirt, foundry sand, paint, oil, galvanised
or soldered metal, all of which are elements which give rise to the emission of dust and fumes
(organic or metallic). The second category relates to chemical reactions at high temperatures,
(e.g. while holding or adjusting the metal composition), which can give rise to metallurgical
fume due to oxidation.
51
r
Emission Charging
Emission Melting
41r
EmissionMelting
EmissionPouring
Additionally the refractory lining (acidic-S10 2, neutral-Al 203, or basic-Mg0) may add a small
amount of dust particles to the emission. It is difficult to obtain average emission data since
the charge cleanliness, which is the dominant contributor to emissions, varies from unit to
unit to a great extent.
Emission rate from an induction furnace depends upon the charge material which again
depends upon the product being made from that furnace. If the product being made is a
good quality casting then emissions are of the order of 1 to 2 kg/tonne metal charge but
if it is ingot vvhich then emission rates of the order of 10 to 20 kg/tonne metal charge are
normal. The highest emission rates occur during charging and at the beginning of the melting
cycle. Particle sizes range from 1 100 micrometer, with more than 50 % being smaller than
10-20 micrometer. Charging oily scrap or borings in a cold furnace will lead to the presence
of organic vapours in the exhaust gases.
Sectior
J Study Results
NORTH
The cluster of the induction furnace in this region are mainly located in Mandl Gobindgarh,
52
Ludhiana, Jalandhar and Delhi. 25 furnaces were visited in these clusters for the purpose of
study. The details of the clusters visited are as under:
Sr.
No.
Description
Mandi Gobindgarh/
Ludhiana/ Faridabad
Jalandhar
Delhi
No. of Furnaces
73
30
Capacity (T/heat)
3-10
0.1- 0.5
0.75 2
Average heat time (hrs)
1.75 2.5
1.0
24
Connected Power load (kW)
1500-4000
100-400
750-1250
Raw Material
Scrap 50 -80%
Scrap 55-75% Pig

iron-10-15%
SS scrap -100%
Sponge iron: 20 50%

Fdy returns 15-30%
6
Product
MS billets
SG Iron casting/malleable casting/ CI casting
SS billets
Slag generation
5 15%
5-100/0
5%
Containment system
Swivel canopy hood
Canopy hood
Canopy hood
Air Pollution control system
Mechanical shaking bag Cyclone/ Mechanical

filter/ pulsejet bag filter/ shaking bag filter
venturi scrubber/cyclonic scrubber
Spray tower/
venturi scrubber
SOUTH
The cluster of the induction furnace in this region are mainly located in Belgaum, Coimbatore
and Palakkad. 19 furnaces were visited in these clusters for the purpose of study. The details
of the clusters visited are as under:
Sr.
No.,.
Description
Belgaum
41111(Karnataka)
Coimbatore
(Tamilnadu)
Palakkad
(Kerela)
No. of Furnaces
19
20
20
Capacity (T/heat)
0.15 0.5
0.5-3.0
36
0.75 1.0
0.5 2 .0
2 2.5
Connected Power load (kW)
125-250
400 -1750
1800-3000
Raw Material
Pig iron: 25 40%

Scrap/foundry returns: 60-75%
Pig iron: 20-40 %

Scrap: 60-80%
Sponge iron: 15 40
%, Scrap 60-85 /0
Product
SG Iron casting/CI
casting
SG Iron casting/ CI
casting
MS billets
Containment system
Canopy hood
Canopy hood
Swivel canopy hood
No APCD, hood is
followed by exhaust
stack
Mainly scrubber
(spray/packed bed),
few units have bag
filters
Pulsejet bag filters
Slag
2 -4 %
25%
5 15 %
53
r
EAST
The cluster of the induction furnace in this region are mainly located in Durgapur and Hoogly.
11 furnaces were visited in these clusters for the purpose of. The details of the clusters
visited are as under:
Sr. Description
No.
Durgapur (West Bengal)
Hoogly (West Bengal)
No. of Furnaces
11
14
Capacity (T/heat)
6 15
3-6
2 3.5
24
Raw Material
Pig iron: 10 25% Sponge iron:

70-80% Scrap 5 10%
Pig iron: 0-5 % Sponge iron:

25-50% Scrap: 50-75%
Product
MS Billets
MS Billets
Containment system
Swivel Canopy hood
Swivel Canopy hood
Venturi scrubber/ pulse jet bag

filter
Scrubber/Pulse Jet bag filter
Slag
15-20 %
15 -20 /0
WEST
The cluster of the induction furnace in this region are mainly located in Goa, Pune and Thane.
12 furnaces were visited in these clusters for the purpose of study. The details of the clusters
visited are as under:
Sr.
No.
Goa
Description
Pune/Raigad
(Maharashtra)
Thane
(Maharashtra)
No. of Furnaces
14
12
Capacity (T/heat)
4-5
5-9
0.3-2
2 2.5
1-3
1-2
Connected Power load (kW) 2000-2500
1250-4000
175-750
Raw Material
Sponge iron 60 70%

Scrap: 30-40%
Sponge iron 10 20
% Scrap 80-90%
Pig iron: 20-40 A)

Scrap: 60-80%
Product
MS billets
MS Billets
SG Iron casting / CI
casting
Containment system
Swivel Canopy hood
Swivel canopy hood
Canopy hood
Spray scrubber/bag filters
Pulsejet bag filter
Not provided
Slag
15 18 %
5 -7 %
1 3 %
54
Observations (IFs)
Capacity
The capacity of the furnaces engaged in the manufacturing of SG iron casting and CI
casting varies from 100 kg to 500 kg per heat. The clusters of these furnaces are mainly
located in Jalandhar(Punjab), Belgaum (Karnataka), Coimbatore (Tamilnadu) and Thane
(Maharashtra). The capacity of the furnaces engaged in the manufacturing of MS billets
varies from 4 ton to 9 ton per heat. Now few units have installed bigger capacity furnaces
such as 10 ton per heat to 20 ton per heat with ladle refining furnaces followed by continuous
casting plants. The clusters of furnaces manufacturing MS billets are located in Mandi
Gobindgarh, Ludhiana (Punjab), Palakkad (Kerela), Durgapur & Hoogly (West Bengal) and
Pune/ Raigad (Maharashtra). The capacity of the furnaces engaged in the manufacturing of
stainless steel billets varies from 0.75 2 Ton/heat. One such cluster of furnaces is located
in Delhi.
Heat time
The average heat time of the furnaces engaged in the manufacturing of SG iron casting and
CI casting is 1 hr, 2 hrs in case of furnaces manufacturing MS billets and 3 hrs in case of
furnaces manufacturing SS billets. The heat time is basically depends upon the availability of
power supply. More is the availability of power, lesser is the heat time.
Type and composition of raw material

The composition and nature of the raw material varies from region to region. The furnaces of
northern region engaged in the manufacturing of MS ingots are mainly using dirtiest type of
scarp including dusty, rusty, painted, galvanized and oily scarp to the tune of 50-80%with 20
50% of sponge iron. The power consumption varies from 650 -700 kW per ton of finished
product. The smaller capacity furnaces engaged in the manufacturing of castings are using
clean scrap to the tune of 70% with remaining 30 % as pig iron and foundry returns. Whereas
the furnaces engaged in manufacturing of stainless steel billets are using comparatively clean
stainless steel scrap to the tune of 100%.
The furnaces of southern region engaged in the manufacturing of MS ingots are mainly using
dirty scarp including dusty, rusty, painted, galvanized and oily scarp to the tune of 60 -85%
with 15 -40 % as sponge iron. The smaller capacity furnaces engaged in the manufacturing
of castings are mainly using clean scrap to the tune of 60 -80 % with remaining 20-40 % as
pig iron.
The furnaces located in Durgarpur of eastern region engaged in the manufacturing of
MS ingots are mainly using sponge iron to the extent of 80%, pig iron to the tune of 1020% with remaining as scrap. Whereas the furnaces located in Hoogly are using sponge
iron to the extent of 50% with remaining as scrap with small quantity (around 5%) of
pig iron.
55
The furnaces located in Goa are mainly using sponge iron to the extent of 70% with remaining
as scrap. Whereas in Pune/Raigad, the furnaces are mainly using scrap to the tune of 8090% with small quantity of (10-20%) as sponge iron. The furnaces located in Thane are of
smaller capacity engaged in the manufacturing of casting are mainly using clean scrap to the
tune of 60-80% with remaining 20-40% as pig iron.
Containment system
Most of the furnaces engaged in the manufacturing of MS billets and SS billets have provided
low canopy hoods for the containment of emissions being generated during melting of the
raw materials in the furnace. The furnaces located in the North have provided elliptical
cut in the furnace hood towards the charging side for the ease of the workers for feeding
of the raw material into the furnace. The raw material is being charged into the furnace
continuously throughout the cycle time. Generally one furnace has two crucibles. The
canopy hoods have been provided with swiveling arrangements so as to serve both the
crucibles of the furnace. The swiveling arrangement is being operated manually. The bigger
furnaces having capacity more than 8 ton per heat have installed electrically controlled
swivel hoods. The gap between hood and furnace was observed to be around 6 inches to
15 inches.
The furnaces located in the southern region engaged in the manufacturing of MS billets have
provided pivot arrangement for swiveling the hood for serving both the crucibles on the
pouring side of the furnace with underground ducting to the APCD. This arrangement was
found to be effective as it provides no hindrance to the movement of overhead crane on the
platform.
Swivel arrangement with underground ducting
56
One of the industries located in western region have installed suction hood which was
observed to be quite effective keeping the operational problems during charging of the raw
material in view. The photographs of the same is as under.
Suction Hood
The smaller furnaces engaged in the manufacturing of casting have installed canopy hoods
with gap between the furnace and the hood as 0.3 -0.5 m as observed in northern region
and 2 -3 m in case of southern region. The emissions from these furnaces were found to be
on the lower side as these industries are using clean scrap. Most of the industries have not
provided with any swiveling arrangement as the furnace is having one crucible only.
Cooling of the Flue Gases

Most of the furnaces in the northern region do not provided any arrangement to bring down
the temperature of the flue gases. This may be due to the fact that the APCD are provided at
a distance of 150-200 feet away from the furnace. Few of the furnaces have provided cooling
duct and water heat exchanger for cooling the flue gases. Where as the industries located in
southern region have provided gas coolers to bring down the temperature of the flue gases.
The industries in the eastern and western region have mostly provided water heat exchanger
to cool down the flue gases.
Air Pollution Control System

The industries have provided mechanical shaking bag filters, pulse jet bag filters, cyclonic
scrubbers and venturi scrubbers for the control of suspended particulate emissions.
Whereas the smaller furnaces engaged in the manufacture of castings have provided spray
scrubber/ mechanical shaking bag filters for the control of particulate emissions. It has
57
been observed that most of the air pollution control devices provided by these industries
are locally fabricated with provision of local made ID fans. The suction efficiency of these
systems was found to be inadequate because of leakages in the bag filter and poor design
of ID fans w.r.t. air handling capacity and pressure. Some of the facts observed are as
under:
Some of the furnaces especially engaged in the manufacturing of castings have provided bag filters, the bags of which are being made from the local available clothes
with poor stitching. This would result in poor filtration.
Most of the industries are not disposing off the dust from the bag filters on regular
intervals resulting in excessive pressure drop across the bag filter leading to poor
suction efficiency.
No instruments like manometers were provided to check the pressure drop across the
bag filter so as to identify the leakages/ chockage of the bag filters.
No maintenance schedules for checking the bag filters/scrubbers, ID fans are being
followed.
Most of the industries do not have any record regarding their dust generation from
the air pollution control systems. This may due to the fact that either they are not
operating the system regularly or not having dedicated man power to operate and
maintain the system.
Most of the smaller furnaces engaged in the manufacturing of castings located in the
southern region have not provided with any air pollution control systems. The furnaces were provided with only high canopy hoods followed by an exhaust chimney to
vent out the flue gases.
Emissions from the sheds because of poor efficiency of APCDs
58
The emissions from the smaller capacity furnaces (100 -500 kg per heat) manufacturing castings and stainless steel billets were observed to be on the lesser side as the
raw materials being used by theses industries are comparatively clean.
One industry namely in the southern region have provided on-line PM monitoring kit
in the outlet chimney to monitor the PM levels. The cost of the kit as informed by the
industry is Rs. 3.5 lacs.
Emissions from the sheds because of poor efficiency of APCDs

The emission monitoring includes particle size distribution, performance evaluation of the air
pollution control technology, work zone monitoring and ambient air monitoring. The results
of the monitoring are tabulate as under:
Particle Size Distribution

Particle Size
Product
Raw Material
Composition
0-2
2-10
10-20
20-30
30-40
40 & above
North
Unit A
MS billets
Scrap: 80-90%
Sponge Iron:
10-20 %
4.13%
17.57%
10.70/0
5.00%
6.60%
56,00%
Unit B
SS billets
South
Unit C
MS billets
SS Scrap: 100% Scrap 85%

Sponge iron
15%
35.00 %
0
32.21%
6.54 %
9.55 %
9.91 %
7.40 %
9.67 %
4.30 %
11.00 %
11.54 %
62.93 %
East
Unit D
MS billets
Pig iron 20%

Sponge Iron
70% Scrap 10%
41.60 %
28.30 %
7.60 %
4.80 %
3.80 %
13.90 %
West
Unit E
MS billets
Sponge Iron
10-20% Scrap
80-90%
5.80 %
19.20 %
21.00 /0
11.40 %
17.60 %
25.00 %
59
It has been observed that particle size percentage varies with respect to the variation
in the composition of the raw material from region to region.
The particle size percentage in case of Unit B is totally different as the industry is using 100% stainless steel scrap for the manufacture of SS billets.
It has been observed in case of Unit D metal cast that more is the percentage of
sponge iron used, more is the percentage of fine particles whereas it is found to be
otherwise in case of industries using less percentage of sponge iron.
Performance monitoring of the pollution control system
SI.
Description
South
Unit C
North
Unit A
Unit B
East
Unit D
111111,
9
Capacity (Ton/heat)
7& 5
Raw Material
Composition
Scrap: 60-70
% Sponge
Iron: 30-40 %
SS Scrap:
100%
Scrap 85%
Sponge iron
15%
Pig iron 20%

Sponge Iron
70% Scrap
10%
Sponge Iron
10-20% Scrap
80-90%
Product
MS billets
SS billets
MS billets
MS billets
MS billets
Design flue gas

volume (Nm3/hr)
8800
4944
16250
Technology for
pollution control
Venturi
Scrubber
Spray tower
Gas Cooler
followed by
Pulse jet bag
filter
Venturi
Scrubber
Pulse jet bag

filter
Monitoring Results
Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet
4
0
11=th
gi_ ii
410_
SI.
No.
Description
Fluegasvolume
Nm3/hr
8735
8081
6492
6304
16279
19738
9818
9683
16841
20206
Temperature
(C)
138
43
47.4
41
60
49
56
45
138
62
Velocity
sec)
14.90
11.55
9.86
10.25
18.6
2.68
22.8
9.83
16.78
3.57
PM (mg/Nm 3
1307
112
185
92
1 31.2
45.9
153
60
1874
133
PM (kg/tone)
4.56
NO (mg/Nm 3)
VOC as Total
hydrocarbons
60
(m/
1.2
0.71
0.42
10.52
47
ND
ND

8
Work Zone SPM (8 hourly sample) (mg/m3)

APCD Working
APCD Not
Working
3.33 (12 hrs)

-
2.40
4.58
0.0325
0.0726
1.27
3.37
3.90
4.72
Ambient Air Quality Monitoring Of Unit A
Sampling Stations
APCD ON
SPM (Ng/m3)
L 1st day
uration or Sample
Station 1 (roof of labour room)
412
Station 2 (Near the scrap storage area)
688
Station 3 (Roof of hazardous waste storage room)
340
APCD OFF
SPM (Ng/m3)
2nd day
(13.00-18.00 hrs)
464
Ambient Air Quality Monitoring Of Unit C
Sampling Stations
APCD ON (1st day)

APCD OFF (2nd day)
RSPM NRSPM
TOTAL
RSPM
NRSPM
TOTAL
(Ng /m3) (Ng/ m3) SPM (ma (Ng/m3) (Ng/ m3) SPM (Ng/
rDuration
m3)
of sample -8 lull
(12.40-20.40 hrs)
Station 1 (Western side of
Duration of sample -4 hrs

(11.20-15.20 hrs)
100.37
11.85
112.220
2753.030
759.09
3512.12
94.259
10.740
104.999
759.689
220.930
980.619
Induction Furnace No. 2 (42

m from furnace no. 2)
Station 2 (Eastern side of

Induction Furnace No. 1
(142 m from furnace no. 1)
Ambient Air Quality Monitoring Of Unit C
Sampling Stations
APCD ON (1st day)

1 OFF ( 2 nd day)
SO2 N
3
NO,
O,
(pg/m )
(pg/m3)
(Ng/m3)
(Ng/m3)
of sample -4
I hrs (11.20-15.20 hrs)
di
li Sot
ill
STATION 1 (Western side of Induction Furnace

No. 2 (42 m from furnace no. 2)
Sample 1
(Duration 4 hrs - 12.40 to 16.40 hrs)
Sample 2
STATION 2 (Eastern side of Induction Furnace
No. 1 (142 m from furnace no.1)
Samplel
Sample2
0.0606
0.0905
0.0303
0.0603
0.0303
0.0603
0.0303
0.5097
0.6339
0.2018
0.2415
0.0301
61
Ambient Air Quality Monitoring Of Unit E

Sampling Stations
Station 1 (Near Scrap Yard)

Station 2 (Near Office Terrace)
APCD ON
RSPM
SPM
(Ng/m3)
(Ng/ m3)
Duration of sample 8 hrs (15.00 -23.00 hrs)
151
221
Station 3 (Near Gas Plant)
93
253
289
534
Observations on the monitoring resultsIFs

Unit A
The performance evaluation of the technology was carried out by simultaneously putting two samplers before APCD and after APCD. The PM concentration before APCD
and after APCD was found to be 1307 mg/Nm 3 and 112 mg/Nm 3 respectively with
efficiency of venturi scrubber as around 92%.
No VOC was detected at the inlet of APCD.
The SPM levels in the work zone during APCD in operation was found to be 3.33 mg/
Nm 3 against the permissible limit of exposure (time weighted average concentration
of 8 hrs) of 10 mg/Nm 3 as indicated in the Factories Act, 1942. The sampler during
work zone monitoring was placed at a height of 1.8 m from the floor and at a distance
of 5 m from the furnace.
The SPM concentration in the ambient air during APCD in off condition was found
to be 1442 pg/m 3 at station 2 against 688 microgram/m 3 during APCD in operation.
The SPM concentration at this station was found to be higher in comparison to other
station because of the direction of the wind was towards this station. During ambient
air monitoring, three samplers were placed at an angle of 120 with each other at a
height of around 10 feet from the ground.
Unit B
The PM concentration before APCD and after APCD was found to be 185 mg/Nm 3 and
92 mg/Nm 3 respectively with efficiency of spray scrubber as around 50%.
The SPM levels in the work zone during APCD in off condition was found to be 4.58
mg/m 3 and 2.40 mg/m 3 during APCD in on condition against the permissible limit of
exposure (time weighted average concentration of 8 hrs) of 10 mg/Nm 3 as indicated
in the Factories Act, 1942.
Unit C
The PM concentration at the inlet of the APCD was found to be 245.9 mg/Nm 3 against
1307 mg/Nm 3 found in case of Unit A. The PM concentration was found to be very low
and the factors responsible for the same are as:
62
Longer process heat time (3.5 hrs) against heat time of 2 hrs in case of Unit A
The industry was using comparatively clean and shredded scrap in comparison to
Unit A.
The air handling capacity of the APCD in case of Unit C for their 6T furnace was
found to be 16,250 Nm 3/hr in comparison to 8800 Nm 3 /hr in case of Unit A for their
5T furnace. The flue gas volume was found to be 95% higher than Unit A against
20% higher capacity of the furnace. It indicates that a lot of dilution is taking
place.
The efficiency of the pulsejet bag filter was found to be 47% only against the desired
efficiency of more than 95%. This may be due to the non maintenance of the bag
filter.
No VOC was detected at the inlet of the APCD
The concentration of NOX at the inlet of APCD was found to be 47 mg/Nm3.
The SPM levels in the work zone during APCD in operation was found to be 0.0325
mg/m 3 and 0.0726 mg/m 3 during APCD in off condition against the permissible
limit of exposure (time weighted average concentration of 8 hrs) of 10 mg/Nm3
as indicated in the Factories Act, 1942. The sampler during work zone monitoring
was placed at a height of 1.6 m from the floor and at a distance of 3 m from the
furnace.
The SPM concentration in the ambient air during APCD in off condition was found to
be 3512.12 microgram/m 3 against 112.22 microgram/m 3 during APCD in operation.
The SPM levels of 3512.12 microgram/m 3 was found to be on the higher side in comparison to work zone SPM levels of 72.6 microgram/m3.
The levels of SO 2 and NOx were also monitored in the ambient air. The concentration
of SO2 and NOx was found to be less than 1 microgram/m 3 during APCD in off condition.
Unit D
The PM concentration before APCD and after APCD was found to be 153 mg/Nm 3 and
60 mg/Nm 3 respectively with efficiency of venturi scrubber as around 40% against
the desired efficiency of more than 90%. The PM concentration of 153 mg/Nm 3 before APCD was found to be very low in comparison to the PM concentration of 13071874 mg/Nm 3 observed in case of Unit A & E
mg/m 3 and 1.27 mg/m 3 during APCD in on condition against the permissible limit of
63
Unit E
The PM concentration before APCD and after APCD was found to be 1874 mg/Nm3
and 133 mg/Nm 3 respectively with efficiency of pulse jet bag filter as 93%.
mg/m3 and 3.90 mg/m 3 during APCD in on condition against the permissible limit of
The SPM concentration in the ambient air during APCD in operation was found to be
in the range of 221-534 pg/m3.

The induction furnaces are basically of two types i.e. smaller furnaces upto capacity of 1T/
heat and bigger furnaces having capacity more than 1T/heat to 20T/heat. The clusters of
the smaller furnaces are located in Jalandhar (Punjab), Belgaum (Karnataka), Coimbatore
(Tamilnadu) etc. The smaller furnaces are basically engaged in the manufacture of SG Iron,
Malleable & CI Castings. These furnaces are using clean scrap (MS & CI) with small quantity of
pig iron. The dust emissions from these furnaces were observed to be negligible as compared
to the dust emissions being observed in the furnaces manufacturing MS billets. Most of the
smaller furnaces located in the northern region have installed low canopy hoods for the
containment of dust emissions followed by bag filters. Whereas most of the furnaces located
in southern and eastern regions have installed high canopy hoods followed by an exhaust
chimney to vent out the flue gases. The suction efficiency of these systems was found to be
poor as the air pollution control systems in this category of furnaces are manufactured and
supplied by the local fabricators.
The furnaces manufacturing SS billets are using comparatively clean SS scrap to the tune
of 100%. The PM levels at the inlet as well as the outlet of air pollution control system was
monitored and found to be 185 mg/Nm 3 and 92 mg/Nm 3 respectively with efficiency of spray
scrubber as 50%. The dust emissions from these furnaces was observed to be on the lower
side as compared to the furnaces manufacturing MS billets because of the comparatively
clean nature of the scrap.
The capacity of the induction furnaces manufacturing MS billets varies from 3 T/heat to 20
T/heat. The clusters of these furnaces are located in Mandigobindgarh / Ludhiana (Punjab),
Palakkad (Kerela), Durgapur (West Bengal) and Raigad (Maharashtra). These furnaces are
using dirty scrap including dusty, rusty, painted, galvanized and oily scrap with sponge iron.
The furnaces located in northern and southern regions are using sponge iron to the extent
of 50% whereas the furnaces of eastern region are using sponge iron to the extent of 80%
with remaining as scrap. The dust emissions from the furnaces using more quantity of scrap
(80-90%) were observed to be high as compared to the furnaces using more quantity of
sponge iron (70-80%).
64
7.1 Containment system

It has been observed that most of the induction furnaces have provided low canopy
hoods for the containment of dust emissions being generated from the furnaces during
melting of the raw materials. The raw materials i.e. scrap and sponge iron are being
charged into the furnace through out the cycle time of around 2 hrs. In low canopy
hoods, the distance between the furnace and the hood is being maintained as 0.4- 0.8
m. It has been observed that most of the furnaces are not able to keep the hood on the
furnace because of the operating problems faced during poking of the charge materials
into the furnace and the irregular size & shape of the scrap. Moreover the suction of the
emissions into the hood was also affected by the man cooler installed on the charging
platform and the cross currents. Although the man cooler is being provided for the
comfort of the workers because of the intense heat on the platform but the workers are
using this high RPM fan to throw away the dust emissions / fumes being generated from
the furnace. Moreover it has been observed that number of industries is upgrading their
furnace capacity without upgrading the capacity of the pollution control device. This
would lead to poor suction efficiency of the air pollution control system with high dust
levels in the work zone environment. The dust coming out from the sheds would further
deteriorate the quality of the ambient air.
The containment system shown in the figure below was found effective in containing the
emissions in some of the units.
TO VENTURI
SCRUBBER
VOLUM
CONTROL
DAMPER
Air Cooled
Duct (A.C.D)
was Flow
80
.--, 0770
r 200022503900
,-- 3900-225O-
4383
077
Fixed side
Suction Hood
Crucible Furnace
PLAN (CONTAINMENT SYSTEM) 01000
Swivelling
type Hood
65
TO VENTURI
SCRUBBER
FIXED SIDE
SUCTION
HOOD
VOLUM
CONTROL
DAMPER
Swivelling
Arrangement
700
0200(H T
1200
3600
0770
041
IFNUDRUIE
NAC N
CRUCIBLE
01000
0
-1100
ELEVATION
(CONTAINMENT SYSTEM)
In the above said containment system, the hood is placed at a height of 1.2 m above the
furnace so that the workers will not face any problem during poking of the raw materials
and irregular size & shape of the scrap. Two side hoods are proposed to take care of the
cross currents. The pivot arrangement for swiveling the hood is proposed on the pouring
side of the furnace with underground ducting to air pollution control device. This type of
arrangement will not provide any obstruction to the movement of overhead crane. The
proposed containment system would increase the volumetric flow rate requirements.
Alternatively for the furnaces which are using clean scrap and keeping the lid of the furnace
closed during melting of the raw materials in the furnace, annular ring shall be provided
Side Suction
Charging
Platform
Induction
Furnace
Spout
Flexible / Swivel
Connection
To APCD
Containment System
66
along the circumference of the furnace with side suction so as to contain the emissions. The
figure showing the same is as under:
7.2 Air Curtain
Most of the furnaces are using man-coolers installed on the charging platform to provide
comfort to the workers working near the furnace area because of intense heat. But it has
been observed that the workers are directing these man-coolers towards the furnaces to
throw away the high temperature dust emissions being generated during furnace operation.
This would result in poor suction efficiency of the air pollution control device with high dust
level in the work zone environment as well as in the ambient air. To counter this effect, some
of the industries have installed APCDs of higher air handling capacities with higher energy
consumption.
An air curtain is recommended to be provided to provide the cool air to the workers without
interfering with the operation of APCD. The schematic arrangement of the air curtain is
shown as under:
WORKING PLATFORM
500
R1200
R2400
PLAN
67
7.3 Air Pollution Control Technology

The induction furnaces have either installed bag filters (mechanical shakers/pulse jet) or
scrubbers (cyclonic/venturi) for the control of Particulate Matter (PM). These furnaces
are using dirty scrap including oily, painted and galvanized scrap with sponge iron. As
already mentioned, the hoods are placed at a distance of 0.4-0.8 m from the furnace.
The dilution of air because of this gap between the furnace and the hood would result
in temperature drop of the flue gases. As the pollution control devices are installed at
a distance of 50-70 m from the furnace, the temperature of the flue gases falls below
the dew point and the condensation will take place. Moreover care has to be taken with
respect to the presence of oil in the scrap, as oily vapour could condense on the filter
cloth, where it could block the pores and make the removal of adhering dust impossible.
As a result the bag filter got chocked resulting in excessive pressure drop across the bag
filter. This leads to poor suction efficiency and increased in the SPM levels of the work
zone and ambient air environment. Hence bag filters does not seem to be technically
feasible.
During emission monitoring, the maximum concentration of PM before air pollution control
device was observed to be 1874 mg/Nm 3 . Keeping the sticky and corrosive nature of the
dust in view, it is proposed that venturi scrubber is the only technically feasible solution for
the control of PM from the induction furnaces especially for the those which are using oily
and galvanized scrap. The PM levels of 150 mg/Nm 3 can be achieved economically with
venturi scrubber having performance efficiency of 92%. This efficiency can be achieved with
a throat velocity of 250 fps with pressure drop as around 20 inch. The collection efficiency
of the venturi scrubber is 100% for the particles above 4 micron, 97% between 2- 4 micron,
80% between 1 -2 micron and 65% below 1 micron. In the case of venturi scrubbers, ph of
scrubbing liquid should be maintained up to 8.5 by adding any alkali like caustic soda or soda
ash etc. Then the turbidity, total suspended solids (TSS), chemical oxygen demand (COD),
iron etc. will be within the limits.
However the bag filter technology can also be applied for the control of suspended particulate
matter for the induction furnaces using non oily and non galvanized scrap. The bag filter shall
be provided in compartments preferably in five compartments with 25% extra capacity so as
to attend the necessary repairs/replacements without interrupting the furnace operation.
7.4 Total cost of the APCD
Type of APCD
Venturi Scrubber
Bag Filter
Capital cost (Lacs)
20
50
0 & M cost/annum Total 0 & M cost/annum con(Lacs)

sidering life of equipment as 7
years (Lacs)
10
12
13
19
The annual turnover of 5 T/heat IF manufacturing MS ingots was reported to be around 50

crores. The environmental cost works out as 0.4% of the annual turnover much below the
limit of 3% as per the requirement of National Enviornment Policy 2006.
68
7.5 Treatment of Slag

Like dust generation, slag forming is an indispensable part of the steel making process and
can not be prevented or controlled totally. The slag amounts to about 250-750 kg/ton of steel
produced depending upon the raw material to be used. More is the quantity of sponge iron
used, more is the generation of slag. Ferrous slag components are separated by magnetic
precipitators. The slag has to be crushed, screened and sized for use.
Depending on the actual composition, the slag can be used for road construction and for
making concrete blocks after grinding as a replacement of coarse aggregates. The deciding
factors with respect to these uses are environmental acceptability and structural suitability.
69

CHAPTER IV: RECOMMENDED STANDARDS

Minimal National Standards for Electric Arc & Induction Furnaces
Based on the findings of the study, following standards have been proposed:
Industry

Electric Arc &

Induction Furnaces
Parameter Emission Standard (mg/ Nm 3)
Particulate Matter
Existing Unit
100
New Unit
50
Load/ Mass standard

Kg/ tonne of steel melt
Existing Unit
New Unit
0.4
0.2
Note: the unit shall channelize their emission through a stack/ chimney of atleast 30 (thirty)
metre above ground level or atleast three metre above top of shed/ building whichever is
more.
Guidelines:
Fugitive Emission Control: The particulate matter should not exceed 2000pg/m 3 at a distance
of 3-10 m from major dust generating source from electric arc and induction furnaces.
Solid Waste Management:
Dust from bag filter if found hazardous it should be handled as per Hazardous Waste
management Rules (1989) as amended till date. Or it may be recycled in the process by
making pellets, etc.
Slag may be crushed, screened and sized for use in road construction or making concrete
block depending on composition.
The above proposed standards have been approved by the Peer & Core Committee and
thereafter by the Central Board. The approved standards have been forwarded to Ministry of
Environment & Forests for consideration for Notification.
70
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Water cooled panels are installed to replace refractory material in the furnace. Water cooled
panel for wall lining and water cooled roof can reduce the basic refractory consumption to a
great extent because more than 75% of the side wall and more than 80% of roof area are
replaced by water cooled system. Apart from the hearth and the wall adjacent to the slag
line where refractory bricks will continue to be used, water cooled panels can replace the
conventional refractories in all other areas.
The furnace walls and roofs have been lined with water panels, providing the opportunity
to save refractory material and also to reuse waste heat by the application of measures for
energy recovery. The economic viability of recovery of energy has to be checked on a plant
to plant basis. An additional energy consumption by water cooled side walls and roof of about
10-20 kWh/t is assumed to be compensated by advantages in the field of plant availability and
maintenance. These water cooled panels allow larger melts due to the increase available area
for the charge. A bag house that is performing efficiently may be over loaded by increased
dust load from each heat.
5.1.3 Oxy-fuel burners and Oxygen lancing:

The conservation of electrical energy to the EAF has been a matter of primary importance
and has been achieved by substituting a part of the electrical energy with oxygen lancing
and oxy-fuel burners. This, in turn, increases productivity because of reduction in tap to tap
time.
The position of electrodes in the electric arc furnace leads to hot and cold spots around the
circumference of the furnace, leading to increased power consumption. In order to overcome
the cold spot problem and at the same time to increase the rate of melting, so as to reduce
the tap to tap time, oxy-fuel burners are used. The use of excess oxygen(10-20 %) results
in inflammable materials charged with the scrap being combusted inside the furnace rather
than in the exhaust system. Operationally between 3-10 Its of kerosene or fuel oil per ton of
steel are used together with 6-20 cubic meter of oxygen. Upto 50 kWh of electrical energy
can be supplied by the use of oxy-fuel burners to increase the melting rate by about 15%.
Automatic lance manipulators are also being used for injection of oxygen and carbon fines,
required for foamy slag practice for effective power inputs and minimizing heat losses. Every
cubic meter of oxygen input is equivalent to a saving of about 4 kWh/ton liquid steel. Usually,
additional energy input by oxy-fuel burners and oxygen lancing results in a decrease of total
energy input required. Adding an oxy burner in the electric arc furnace increases the heat.
This additional energy reduces the melt time, causing an increase in grain loading over a
shorter period of time.
5.1.4 Electrode Controllers

Effective automatic electrode control is one of the most important factor in efficient arc furnace
operation since the energy consumption, melting time, electrode and refractory consumption
as well as the load factor presented to the supply system depends largely on the speed and
precision with which the electrodes are controlled and positioned in the furnace.
72
Developments in solid state technology has helped to evolve thyristor controls for electrode
movement. Energy requirement for a thyristor controller is bare minimum and it has also
been reported that the response of thyristor controllers is better as compare to that of other
controllers.
5.1.5 Waste Heat Recovery
Pre-heating of scrap is a practice to tap the waste heat in the exhaust gases. The temperature
to which the scrap can heated depends on the duration of the heat and the heating
arrangements. Scrap pre-heated to a temperature of 300-600C leads to reduction in tap
to tap time by 8-10 minutes and a saving of 30-40 kWh/t in electrical energy. The cost of
equipment required for scrap pre heating of capacity 10-15 ton will be about 70-80 lacs. This
would lead to reduction in dust emissions in the flue gas. However, this option needs to be
evaluated thoroughly with respect to economic viability.
During the project studies, it was observed that one of the units at Maharashtra had
explored the viability of heating the scrap through waste gases. The industry achieved
reduction in energy consumption by 25-30 kWh per ton of steel produced with a capital
investment of Rs. 50.0 lacs whose present value is around Rs. 1.5 crores. Presently
the industry is not practicing the pre heating of scrap because of following practical
problems:
The system was found to be only viable for units using 100% shredded scrap as other
raw materials such as turning & boring and sponge iron gets partially melted in the
pre-heating chamber. This would result in chocking of the system. Whereas only small
rise in temperature was found in heavy scrap.
Difficulty in taking out the pre-heated raw material from the pre-heating chamber
thereby resulting in production loss.
Pressure drop across the pre heating chamber (around 100 mm) leads to increase in
energy consumption of the ID fan.
Formation of organic emissions and dioxins
Excessive pressure drop across the pre-heating chamber thereby requiring more energy to
suck the emissions from the furnace.
5.1.6 Eccentric Bottom Tapping (EBT)
The practice of EBT is widely adopted now a days, as it makes possible slag free tapping with
tapping angle of about 12 against 12 0-42 in non EBT furnaces. It also allows cost savings
for the lowering of refractory material needed, reduction in tap to tap time, reduction of heat
losses and shorter power cables. Bottom tapping is beneficial for maintaining low nitrogen
levels because tapping is fast and a tight tap stream is maintained. Usually most of the new
electric arc furnaces are equipped with EBT systems.
73
5.1.7 Automation
Computer control in electric arc furnace plants has become necessary within recent years,
as the high throughputs require efficient control system to manage the material and data
flows arising in the raw material selection, EAF, ladle furnace and continuous casters. Efficient
control systems permit an increase in productivity, a reduction in energy consumption and
also a decrease in dust emissions.
5.1.8 Ladle or Secondary metallurgy
Some production steps need not to be carried out in the EAF itself and can be performed
more efficiently in other vessels (like desulphurising, alloying, temperature and chemistry
homogenization). These tasks have been shifted from the EAF to ladle furnaces. The reported
benefits of this development are energy savings (net savings of 10-30 kWh/ton), a reduction
of tap to tap times of about 5-20 minutes, increasing the productivity, a better control of
temperature of the heat delivered to the caster, a possible reduction of electrode consumption
(up to 0.1-0.74 kg/t), alloy savings and a decrease of the emissions from the EAF itself. A
possible drawback of using ladle furnaces with respect to air pollution control is the increase
in the number of emission sources and requiring higher expenditure for air pollution control
equipment.
5.1.9 D.C. Arc Furnaces
The DC arc furnace is similar to conventional AC arc furnace in metallurgical operation with
better stirring of liquid bath. A major problem faced by AC arc furnace operators is that
of "flicker", which is dependent on the strength of the local power grid. Consequently in
areas with low or insufficient grid strength, it becomes necessary to install costly flicker
compensation equipment to mitigate the harmful effects of EAF operation on the utility grid.
Essar steel set up India's first DC arc furnace.
The DC arc furnace has single top graphite electrode instead of three graphite electrodes. Roof
is similar to conventional water cooled/refractory roof with single hole for electrode entry. In
AC arc furnace, there are 8-10 operations of circuit breaker during melting of one heat. The
circuit breaker in AC furnace is tripped during short circuiting, charge collapse, tap changing,
charging and electrode addition. Whereas in DC arc furnace, circuit breaker is not switched
off, instead thyristors are switched off thereby minimizing costly maintenance of high voltage
circuit breaker. Bottom electrode is the major component of DC arc furnace through which the
liquid bath is continuously stirred. This leads to homogenization of chemistry and temperature
of liquid metal bath. In AC arc furnace, temperature distribution on the surface is not uniform
due to flaring of arcs and hence cold spots form in the furnace. DC furnace is more effective in
terms of bath stirring enabling faster scrap melting with no risk of un-melted scrap and flow of
current causes better stirring of liquid metal. If we compare the AC arc furnaces with DC arc
furnaces, following advantages of DC arc furnaces would be observed:
Decrease in tap to tap time by 5%
Decrease in electrical energy consumption by 5-7%
74
Temperature uniformity due to better stirring

Low electrode consumption (reduction by 50% e.g. in a 30 ton DC arc furnace, electrode consumption is 1.8 kg/t against 3.5-4.5 kg /t in AC arc furance)
Considerable reduction in Flicker (by over 50%)
One electrode arranged in the centre prevents any local refractory lining over heating
Reduced maintenance of various parts like electrode holder, electrode drives, high
voltage switchgear etc.
Less expenditure on pollution control system because of lesser generation of emissions.
Improved environmental conditions due to less noise during furnace melting and
working.
5.1.10 Single Electrode DC Ladle Refining Furnace

The experience on single electrode DC ladle refining furnace has been quite successful. The
power consumption for a 7MT furnace was found to be 80 kWh/t with electrode consumption
of 0.25 kg/t. The processing time varied from 35-45 minutes.
It was not possible to make smaller capacity LRF with AC power because of 3 electrodes. It
is now possible to go for very small capacity LRF such as 4-5 MT with single electrode. Argon
consumption of DC LRF was same as AC LRF i.e. 1-2 Nm 3 argon/hr.
5. 1.11 Energy Efficiency in Steel Industry

Steel foundry industry is an energy intensive sector. Adequate energy management can save
about 10% of electrical energy consumption. The energy consumption per ton of metal can
be brought down by:
Scrap preparation:
The bulk density and the scrap size have a close relation with the specific energy consumption.
It is quite important to reduce the number of back charges per heat, as it results in less
frequent opening of furnace root which reduces the heat losses. Each reopening of the
furnace is expected to increase energy consumption (Refer Tablel).
Table-1 Energy Loss in Relation to the Duration of Roof Opening

Minutes
0
2
4
6
8
10
12
kWh/ton
0
2.5
4.8
7
9.2
11.5
13.8
75
Therefore, it is worthwhile to install presses to reduce the volume of scrap to be charged with
the objective of reducing the charging time. It also reduces melting time by 5-15 minutes
which leads to energy savings of 7-10 kWh/ton against the energy consumption of 2-3 kWh/
ton required for pressing the light scrap (Table 2).
Reductions
Charging time
Melting time
Electric power consumption
Refractory consumption
Electrode consumption
Increase in Yield
Percentage
30 /0
5 ok
10 0/0
1 kg/ton
0.3 kg/ton
4%
Scrap Segregation:
Charging the furnace without segregating the charge according to composition results
in wide variations in opening carbon. Due to high opening carbon, the oxidation period
increases which in turn results in higher power on to tap time with higher specific energy
consumption. Hence the scrap can be segregated as per the carbon content and charging
can be done accordingly as per the requirement.
Oxygen Lancing
In steel making practice, oxygen plays a predominant role for increasing productivity as well
as decreasing over all energy consumption. The use of oxygen during the melting stage
results in reduction in melt down time because of the exothermic reaction of oxygen with iron
and with combustible element present in the scrap. It results in reduction in tap to tap time
and thus saving in specific electrical energy consumption due to reduction in fixed losses in
the furnace. Besides energy savings, uniform melting during each charge can be achieved.
It has been reported that the use of one cubic meter of oxygen per ton of metal will reduce
the specific energy consumption by 4.4 kWh. It has been observed that the economic limits
for oxygen uses is 14-20 cubic meter per ton of metal. Higher values of oxygen injection
results in lower metallic yield. Proper oxygen lancing can reduce power requirement in melting
upto 75 kWh/ton.
Temperature Control
Temperature control of the liquid metal is one of the factors which influence the specific
energy consumption. Optimizing and brining down of molten metal pouring temperature by
10 C can save about 15-20 kWh/t of liquid metal. A higher tapping temperature allowance
is given to take care of:
Heat loss in the ladle
Heat loss during transit
76
Number of openings and carbon content of the steel grade
Heat loss in the ladle: Tapping temperature can be brought down by reducing the heat loss in
the ladle. One of the latest developments to minimize heat loss in the ladle is the blanketing
of the tapped metal in the ladle by an insulating expendable compound. The advantage
of using this compound are reduction in tapping temperature and hence specific electrical
energy consumption, uniform temperature of the melt through out etc. Rice husk ash which
is very high in silica can also be used to reduce the temperature drop in ladles. This can also
be used as insulating filler between the ladle and an outer jacket.
Heat loss during transit: The delay analysis should also be carried out for various stages
right from the lifting of ladle from the ladle pre-heating station to the concast area.
The delay in lifting ladle will cause substantial drop in ladle temperature thus requiring
corresponding increase in tapping temperature. It is advantageous to operate the furnace
at the highest voltage level compatible with satisfactory arc stability, so that the current
is minimum.
After analyzing the data and implementing the corrective measures of reducing heat loss in
ladles and during transit, the standard for tapping temperature should be set so that it is
marginally (about 10-20C) above the sum of liquid temperature and the drop in temperature
at various stages between tapping and the last pouring.
Electrode Consumption
In high or ultra high power arc furnaces, electrode costs can account for up to 15% of
the conversion cost. In addition, electrode performance substantially affects the operating
costs of the furnace. The rising cost of electrodes during recent years have compelled steel
maker to devote greater attention the causes of electrode wear. The most important factor
is oxidation of the electrode graphite. The oxidation rate is largely dependent on the surface
temperature of the electrode and on the velocity, turbulence and oxygen content of the gases
lapping it. The most widely used method of reducing surface consumption consist of coating
the electrode with an antioxidant.
Improved Casting Yield
Optimized yield of finished casting can reduce energy costs. It can be improved by using
computer programme efficient mould designs, ceramic feeder inserts and filters.
Delay analysis
To minimize avoidable delays, it is essential that the reason for the delay be analyzed. For
the purpose of delay analysis, the cause of the delay and its duration should be logged for
a period of 3-6 months. The data so collected should be arranged in such a fashion that the
cumulative delay time for each type of fault, breakdown problem is available at a glance. In
this manner, the major problems causing delay can be addressed so that the benefits in the
form of reduced energy consumption can accrue.
77
Foamy Slag practice

Foamy slag practice involves injection of calcium carbonate and carbon powder into the oxygen
enriched slag. Calcium carbonate cools the slag by endothermic reaction and the carbon
reduces the iron oxide content in the slag and also develops carbon monoxide gas so that the
slag swells up. Foamy slag on top of the melt decreases the required energy input by efficient
energy transfer and in particular the protection of the furnace shell. Another positive effect of
the foamy slag is a reduction in noise caused by the EAF process. It saves refractory material
by protecting the furnace lining from extreme heat radiation. This means a lower amount of
refractory breaks possibly has to be land filled or treated, it also means a saving of internal
input. Foamy slag practice also improves the Fe yield, while reducing the radiative heat losses
from the steel bath. On the other hand, foaming slag has a lower density than normal slag
(1.15 -1.5 t/m 3 compared to 2.3 t/m3 ), so the volume of slag initially obtained increases. It
increases productivity and can be considered as a retrofit measure as well as state of the art in
modern electric steel making. Therefore the effects of the foaming slag practice are:
Reduction in energy consumption (10 kWh/t)
Reduction in electrode consumption (0.7 kg/t)
Reduction in noise level
Reduction in melting and refining time
Improvement in the furnace operating power factor by about 5-10/0 resulting in reduced distribution losses.
Increase in productivity
5.1.12 Auxiliaries
Compressed Air System
Compressed air is one of the major auxiliary load in most steel foundries. Excessive pressure
drop due to inadequate pipe sizing, choked filter elements, improperly sized coupling and
hoses represents energy wastages due to leaking pipe joints and coupling.
Pressure loss in pipe

It is essential that pipes should be sized so as to prevent excessive pressure drop. The
following table (Table 3) demonstrate the pressure loss in pipesl.
Table 3 Pressure Losses in Air Mains

Pipe normal bore mm
40
50
65
80
100
78
Pressure drop (bar) per

100 meters
1.8
0.65
0.22
0.04
0.02
Equivalent power losses

kW
9.5
3.4
1.2
0.2
0.1
To avoid excess energy loss, maximum air velocities in pipes should not exceed 6 m/s
although higher air velocity can be permitted in branch lines of total length less than15 m.
The following table (Table 4) gives the maximum recommended air flow rate for various sizes
of pipes at the normal compressed air pressure of 7 bar gauge (100 psig) for both main line
piping and branch main of limited length.
Table 4 Maximum Recommended Air Flow Rates

Medium weight pipe
BS 1387
Normal bore (inch) exceeding
15 m
Maximum recommended air flow at a pressure of 7 bar gauge

(100 psig)
Main lines (scfm)
Branch lines (scfm)
1/8
1/4
13
3/8
10
29
1/2
20
54
3/4
35
80
54
150
1.25
100
315
1.50
135
470
220
900
2.50
375
1450
500
2600
875
1300
1900
Leakage
Another major opportunity to save energy is the prevention of leaks in the compressed
air system. Leaks frequently occurs at air receiver relief walls, pipe and hose joints, shutoff valves, quick release couplings, tools and equipment . In most cases, leakages are
due to poor maintenance rather than improper installation. The following table (Table 5)
gives approximate power wasted by leaks of various sizes at the normal pressure of 7
bar gauge. The leakages can be detected by regular checking of joints, unions etc with
soap water.
Table 5: Power Wastage through Leaks

Hole diameter (inches) Air leakage at 7 bar gauge Power required to compress air being
(scfm)
wasted (kW)
1/64
0.4
0.1
1/16
6.5
1.0
1/8
23.2
3.5
79
There exists a scope for energy conservation in the compressed air system by constant
maintenance and rectification of leak prone areas. Clean and dry intake air leads to more
efficient compression. For every 4C rise in inlet air temperature, 1% extra energy is
consumed.
Lighting system
Lighting system offers scope for energy conservation if attention is focused on the following
areas:
Efficient lighting system
Efficient lighting control
Pumping system
The pumping system should be analyzed for the type of controls provided. In oversized pumps,
instead of controlling the discharge by throttling, pump should be de-rated by reducing the
size of the impeller, operating the pump at lower speeds.
As constant speed pumps work economically, without undue energy wastage, over a very
narrow range near to the design point, one should endeavor to operate the pump as near to
the design point as possible, without the use of inefficient controls like throttle valves.
Ladle pre heating
Ladle preheating is an energy intensive process, the oil consumption varying from 1030 liters/ton. Some of the units use burners which have been fabricated by the plant
personnel resulting in inefficient and erratic combustion. Substantial savings in energy
are possible by switching over to film burners, by going in for refractory fiber cover
on the ladle and a refractory fiber sleeve in the ladle between the shell and refractory
brick.
5.1.13 General Practices
Demand management
Managing the maximum demand of the plant within specified limits by means of staggering
of loads, shedding non-essential loads during peak hours etc. will bring forth substantial
saving in the energy bill.
A measure of the effectiveness of any demand management programme is an index called
the load factor which is ratio of actual energy consumption to the consumption if the peak
load had continued throughout the day. Improving the load factor by demand management
is not an energy conservation measures but it is an effective method of reducing the energy
bill by pruning the maximum demand.
80
Reactive power compensation

The furnaces have different power factor at different stages of operation. Judicious design
can overcome the problem of low system power factor.
5.1.14 Financial analysis for energy conservation

A correct investment decision of energy conservation measures can be made by employing
financial ratios like payback period, present value method, internal rate of return etc.
5.1.15 Monitoring and Targeting

Monitoring and targeting is an integral part of energy conservation activities. Targets and
standards have to be set to achieve energy efficiency. The process will be complete only if
the management monitor the results on continual basis.
5.1.16 Opening around the Electrodes

The electrode holes in the roof should have a diameter by 40-50 mm greater than the
actual diameter of electrodes in order to prevent damage to the electrodes during heating
of the roof. If the gap between the electrodes and roof is more then much heat would be
lost with the furnace gases evolving through these gaps. This could involve a high loss of
electric energy/heat. In addition, hot gases can heat the electrodes to a temperature above
500C at which the electrodes begin to oxidize intensively. There diameter thus diminishes
and the current density increase. This can result in electrode fracture, resulting in a higher
consumption of electrodes and higher cost of steel produced.
5.1.17 Reduction in number of charging buckets

It has been observed that in most of the electric arc furnaces, the industry is using 2-3 ladles
for the transfer of molten metal from electric arc furnace, to refine the molten metal and
for casting to concast plant. Whereas in one of the units at Mandi Gobindgarh, the industry
is using single ladle for carrying out all these operations. This would help in to reduce the
emissions being generated during preheating of the ladle with furnace oil besides savings in
consumption in furnace oil.
Number of buckets should be as minimum as possible. To reduce this, number the raw
material should be compacted form by using either bundling press or using high density
scarp. Reduction of charging buckets will reduce the total pollution being generated during
roof opening at the time of charging.
5.1.18 Improvement in Secondary Emission Control System

The following points would help in the improvement of a secondary emission control
system:
81
The electric arc furnace enclosed building should be as small as possible for good
ventilation.
The structure of a charging crane should be considered so as not to obstruct the ascending stream from the furnace.
Heat sources in the melt shop should be isolated from the dusting sources e.g. continuous casting area should be isolated from the electric arc furnace area with curtain
walls or fixed walls to permit ascending air in the continuous casting area, which is
not dusty, to be emitted outside without de-dusting.
Where canopy hood is provided above the electric arc furnace to contain the secondary emissions, the location of the hood should be such so that it neither obstruct the
working of overhead crane nor obstruct the movement of electrodes.
During studies, a similar hood was observed in the electric arc furnace of M/s Hindustan
Engg. & Industries Ltd., Hoogly (West Bengal). This hood is placed at a distance of 5'-6'
below the over head crane and around 2' above the electrodes. The hood is being operated
pneumatically. It neither obstruct the movement of overhead crane nor the movement of
electrodes.
5.1.19 Reduction in Electrode Consumption

Graphite electrodes constitute the single biggest consumable in steel making in terms
of cost. 10-15% reduction in electrode consumption is possible by adopting water
spray system for direct cooling of electrodes, a thin water film cools the surface of the
electrode, thus reducing oxidation. Coated graphite electrodes are used to minimize
oxidation loss. This coating also provides and electrically conductive outer skin to
reduce current density and reduces electrode breakage. Thus specific consumption is
reduced by 20-30%.
The electrode consumption gets reduced by 30% when continuous feeding of DRI is applied,
compared to the conventional 100% cold scrap charge practice. This is due to higher
productivity, decreased electrode oxidation, less frequency of roof opening meaning less
thermal shock, less CO in furnace atmosphere and less electrode breakages.
5.1.20 Incorporation of Power Conducting Arms

The present day design of EAFs has incorporated the aluminium box type arms in place
of copper clad arms, thus reducing electrical energy losses, electrode consumption and
manufacturing costs. With the use of aluminum conducting arms, the arc is more stable,
resulting in lower operational reactance and higher active power input.
5.1.21 Productivity
With % DRI in charge below 30%, there has been no increase in productivity. Between 30%
to 70% DRI, the gain in productivity is about one tonne per hour for every 10% DRI increase.
82
The increase in productivity is mainly due to the shortening of conventional refining perid due
to overlapping of melting and refining periods.
5.1.22 Fluid coupling with fan of APCD

Generally the fan is installed at the back end of the pollution control system consumes very
large amount of power. The flue gas volume varies with variation in temperature of the
furnace at different times. It has been observed that the pollution control system which
was designed with respect to peak volume when comes to valley (low volume) because of
variation in temperature, the efficiency of the fan comes down. The fan was observed to be
operating all the time irrespective of whether the furnace was under charging or furnace
was under tapping. When the fumes were not generated even then the fan was running
continuously, may be with the damper partially closed but consuming fairly good amount of
power.
Ne unit at Punjab have installed fluid coupling with the fan so that the speed of the fan
can be varied according to the pollution load. As we know that volume of the flue gases
is proportional to the speed of the fan, the pressure is proportional to the square of the
speed and power consumption is proportional to the cube of the speed. By incorporating
this system, the industry have been able to save considerable amount of energy. The fluid
coupling is only viable for bigger furnaces having pollution control system ID fan capacity
more than 400 HP. The cost of fluid coupling is around 5 lacs. For smaller capacity furnaces,
variable speed derive motors can be used.
5.1.23 Electrode cooling

It is very important to fully control the amount of water which is being put on the
electrodes for cooling purpose. PLC based temperature sensor should be provided for
controlling the amount of water which is totally dependent upon the temperature of the
electrodes. Whenever the furnace is off, the water automatically stops and the melter
does not have to bother about all these things. Otherwise if the operator forgets to
close the valve, then lot of water will go into the furnace and will create a lot of other
problems.
5.2 Electric Induction Furnaces

5.2.1 Energy Conservation
The following operational measures can be adopted to reduce the specific energy consumption
in induction furnaces.
Idling Period:
Idling periods are the periods when the furnace power is switched off, should be kept as
short as possible. Periods of idling are inherent because of the following activities:
83
Charging:
The charging material must be dry in order to avoid explosions. The most efficient way to
charge a furnace is with drop buckets that consume the least time.
Slagging:
Slagging operation is the most energy wasting activity as it is done with power off. The most
advantageous method is the back tilt design which results in minimum movement of the
slagging door and a maximum back tilt angle without blocking the front of the furnace by
ladle traffic.
Sampling:
To conserve heat, samples should be taken through a small sampling cover without opening
the complete furnace cover.
Charge Material:
Cleanliness of charge, charge density and charge size are important parameters affecting the
energy consumption, charging and de-slagging practice. The volume of slag and build up
problems are largely governed by the quality of charge materials. Apart from the cleanliness
of charge material, the charge size is also important and has a bearing on the starting
characteristics of the furnaces especially those of main frequency. Dirty charge constituents
can result in serious de-slagging and built up difficulties. Charge pieces should be at least 8-10"
in dia meter because coil efficiency increases rapidly as diameter initial charge increases.
Molten Heel Practice:

The furnace should be operated with a molten heel size of about two third of the furnace
capacity, for optimum performance.
Furnace Cover Losses:

Furnace door should be opened for the least minimum time to avoid excessive radiation loss.
5.2.2 Charging and Melting

The main charge materials used in an induction furnace are scrap and ferro alloys. For better
and efficient operation of melting, charge should:
Be as dense as possible.
Be clean. Rust oil grease sand etc., should preferably be nil.
Be metallurgically clean, i.e. free from slag lumps, oxides etc., particularly for sponge
iron, skull and ferro alloys.
84
Have less sharp pointed edges, particularly in case of heavy and bulky scrap.
Be segregated from harmful ingredients like explosives closed containers evaporative
substances and readily available in chargeable sizes on the shop floor.
During melting there should be certain quality control as well as energy conservation
measures. These are:
First batch of charge should aim for around 0.20 per cent higher carbon in the bath
than the final chemistry, at about 30per cent melt level, incase sponge iron is to be
added. Otherwise target chemistry is to be maintained.
Sponge iron charging should be over by around 80 per cent of melt level.
Obtain bath analysis at 50 per cent melt level for %C & Mn. At this stage %C & Mn
should be around 0.20_per cent.
Continuous deslaging and not to allow slag crust to form. Enrich slag with carbon
to Fe from Feo. Maintain a protective cover on the molten metal to avoid ingress of
gases.
Maximum possible continuous operation of the furnace.
Proper housekeeping and efficient material flow on the furnace bay in particular.
Continuous charging to maximum possible quantity
Immediate charging and running of the furnace at full power after tapping. First
charging preferably by bucket.
Always run the furnace at full power.
Avoid delay in operation changeovers to reduce heat time.
Avoid excess super heating and bridging.
Use the furnace lid whenever possible.
5.2.3 Heat Finishing & Tapping
Following measures could be adopted during finishing and tapping of a heat.
Crate slag free bath.
Carryout primary de-oxidation by dipping pure aluminum followed by SiMn, wait for
2-3 minutes and then skim off the slag.
Control minimum tapping temperatures and attain it without holding the molten in
the furnace.
85
Check plate samples to ensure killing of bath.

Completely avoid excess superheating.
Employ smooth tapping and avoid any jerk.
Ensure close tap stream.
Liquid metal after complete adjustment, cold either by directly poured into the moulds for
ingot casting or be taken into a ladle for pouring. Post tapping operations are also important
in the light of quality and productivity.
5.2.4 Minimize and control the refractory wall wearing
The refractory life depends on the choice of materials as a function of the slag chemistry
(acidic or basic), the operational temperature (steel, cast iron, non-ferrous), and the care
taken upon relining (sintering). The lifetime may vary from 30 (steel, cast iron) to 100 200
(cast iron) melts. Operational control measures are taken to follow the refractory wear. These
include visual inspection, physical measurement and instrumental monitoring programmes.
Good charging practice measures prevent the cumulative effects of physical chokes and
mechanical stresses. These include the use of automatic charging systems, hot charging,
avoiding high drops and the use of compact and dry scrap.
5.2.5 Change from mains frequency to medium frequency furnaces
Medium frequency (250Hz) furnaces have a higher power density (up to 1000 kW/tonne)
than mains frequency (50 Hz) furnaces (300 kW/tonne). This allows the use of a smaller
crucible (up to a factor of three smaller) which results in a smaller total heat loss. The thermal
efficiency of medium frequency furnaces is 10 % higher than for the mains frequency types.
Additionally, mains frequency units need to be operated with a molten heel of up to 2/3
of the crucible capacity to optimize specific energy consumption and also require specific
starter-blocks for cold start-up. Medium frequency furnaces can readily be started with a cold
charge and can be emptied at the end of each working shift or melting batch.
86
CPCB Brings out reports under the COINDS Series :
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COMPREHENSIVE INDUSTRY DOCUMENT SERIES

Comprehensive Industry Document on

Central Pollution Control Board

CPCB brings out Reports under the following series:

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COMPREHENSIVE INDUSTRY DOCUMENT SERIES:

COMPREHENSIVE INDUSTRY DOCUMENT ON

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CPCB, 200 Copies, 2009-10

('in eita)1{ fl kiiia41)

Central Pollution Control Board

'Parivesh Bhawan' C.BC.D.-cum-Office Complex, East Arjun Nagar, Delhi-110 032

Electric Arc Furnaces

Section 2: Industrial Scenario

Section 3: Manufacturing Process

Section 4: Sources of Air Pollution

Section 5: Field Study Results

Section 6: Emission Monitoring Results

Section 7: Pollution Control Technologies

Electric Induction Furnaces

Section 2: Industrial Scenario

Section 3: Manufacturing Process

Section 4: Sources of Air Pollution

Section 5: Field Study Results

Section 6: Monitoring Results

Section 7: Pollution Control Technologies

Comprehensive Industry Document on Electric Arc & Induction Furnaces

Comprehensive Industry Document on Electric Arc & Induction Furnaces

Lower exhaust gas losses as compared to conventional furnaces.

1.3 Classes of Electric Furnaces

Direct Arc Furnace

Submerged Arc Furnace

SteelStainless Steel Scrap, Mild Steel scrap, Sponge Iron

Comprehensive Industry Document on Electric Arc & Induction Furnaces

The major clusters of EAF/IF are:

Comprehensive Industry Document on Electric Arc & Induction Furnaces

CHAPTER II-ELECTRIC ARC FURNACES

Section 2: Industrial Scenario

Comprehensive Industry Document on Electric Arc & Induction Furnaces

State wise distribution of EAFs

Section 3: Manufacturing Process

Comprehensive Industry Document on Electric Arc & Induction Furnaces

Dephosphorisation and Decarburisation (02 Lancing)

Adjustment of the composition

Fig: Manufacturing Process

Fig: A typical diagram of EAF

Comprehensive Industry Document on Electric Arc & Induction Furnaces

Water Cooled Roof

---Power Conducting Arm,

Fig: Elevation and Plan of EAF

3.1 Inputs to Electric Arc Furnace

Comprehensive Industry Document on Electric Arc & Induction Furnaces

deoxidising :secondary metallurgy

Flow Diagram of EAF process

3.1.1 Raw materials

Comprehensive Industry Document on Electric Arc & Induction Furnaces

A pie chart showing energy input vs output

Comprehensive Industry Document on Electric Arc & Induction Furnaces

3.3 Charging of Raw Material

Charging of Raw Materials

3.4 Melting and Refining of the melt

Comprehensive Industry Document on Electric Arc & Induction Furnaces